CARBOAUTOMATYKA SA

Enterprise of Completion and Assembly of Automation Systems

43-100 Tychy, ul. Budowlanych 168
tel. head office: (32) 323 43 00 fax: (32) 323 43 23 Secretariat: (32) 323 42 42
e-mail: carboautomatyka@carbo.com.pl Internet: www.carbo.com.pl

Bottom Measurement Data Hub

DKDP

February 2018

SERVICE MANUAL - OPERATION AND

MAINTENANCE MANUAL
IDT 107.188 - 2
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Compliance

 The product complies with the basic health and safety requirements
concerning the design and manufacture of equipment and protection
systems for use in hazardous areas as defined in ATEX Directive
2014/34/EU, as well as the following harmonized standards:

PN-EN 50303:2004 (EN 50303:2000)

PN-EN 60079-0:2013 (EN 60079-0:2012)
PN-EN 60079-11:2012 (EN 60079-11:2012)

This compliance was confirmed by a Type EU Examination Certificate

OBAC 18 ATEX 0110X

issued by the Testing, Certification and Certification Center,

OBAC Sp. z o.o.,
Notified Body No. 1461

 This product meets the essential requirements concerning electromagnetic

compatibility (EMC) specified in Directive 2004/35/EC and in the following
standards:
PN-EN 55011:2016-05
PN-EN 61000-4-2:2011
PN-EN 61000-4-3:2007/A2:2011
PN-EN 61000-4-4:2013-05
PN-EN 61000-4-6:2014-04
PN-EN 61000-4-20:2011
PN-EN 61000-6-2:2008
PN-EN 61000-6-3:2008/A1:2012
PN-EN 61000-6-4:2008/A1:2012

 The manufacturer of the product - Enterprise of Completion and

Assembly of Automation Systems „Carboautomatyka” S.A. - issued the
EU declaration of conformity and has marked the product with "CE"
mark.

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Table of contents:
1. LIST OF FIGURES................................................................................................................................................ 3

2. SAFETY INSTRUCTIONS ................................................................................................................................... 4

3. IDENTIFICATION ................................................................................................................................................ 4

4. PURPOSE ............................................................................................................................................................... 5

5. TECHNICAL DATA.............................................................................................................................................. 5

6. DESIGN AND PRINCIPLE OF OPERATION ................................................................................................... 7

7. DEVICE INSTALLATION ................................................................................................................................... 9

8. START-UP ............................................................................................................................................................ 10

9. INCORRECT OPERATION............................................................................................................................... 10

10. MAINTENANCE AND REPAIR INSTRUCTIONS......................................................................................... 10

11.1 MAINTENANCE .................................................................................................................................................. 10
11.2 STOP ANY SD CARD WRITING BEFORE DISCONNECTING THE POWER SUPPLY. ..................................................... 11
11.3 REPLACING THE DKDP_MASTER AND DKDP_ARCHIVE MODULES............................................................. 11
11.4 REPLACING DKDP_FIBER MODULES ............................................................................................................... 11
11.5 REPLACING THE DKDP_LINE / DKDP_4IN_4OUT ACTUATORS ..................................................................... 11
11.6 CONNECTING INTRINSICALLY SAFE LINES TO DKDP .......................................................................................... 11
12. PERIODIC INSPECTIONS .................................................................................................................................. 12

13. EMERGENCY PROCEDURE ........................................................................................................................... 12

14. INSTRUCTIONS FOR THE SAFE DISPOSAL OF THE DEVICE. .............................................................. 12

15. TERMS OF USE DURING THE WARRANTY PERIOD ............................................................................... 12

1. List of figures

Drawing
Name of a drawing
number
Fig. 1 General view of the DKDP Data Center Concentrator
Fig. 2 Cable routing in DKDP - exemplary configuration
Fig. 3 DKDP_FIBER module
Fig. 4 DKDP_MASTER or DKDP_ARCHIVE module
Fig. 5 DKDP_LINE module
Fig. 6 DKDP_4IN4OUT module
Fig. 7 Block diagram of the DKDP Data Center Concentrator
Fig. 8 Description of signals - connection chamber
Fig. 9 Name plate
Fig. 10 DKDP control unit - assembly dimensions

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2. Safety instructions

a) The device can only be installed by specially trained personnel, in accordance with
applicable laws (among others, with regulations concerning electrical equipment
used in explosive areas). This manual is intended for trained personnel only.
b) All installation work must be carried out in accordance with the relevant local
(factory) and national standards.
c) Installation of the device should be carried out strictly in accordance with this
instruction.
d) Before starting any operations, check that the external circuits are properly connected
using appropriate plugs, while maintaining the required creepage clearances.
e) The output circuits of the device can only be combined with intrinsically safe circuits
with parameters corresponding to those specified in the technical data.
f) Intrinsically safe circuits are connected to the device should be routed in mine cables
that meet the requirements of PN-EN 50394-1:
1) in groups of one type A or B cable
or
2) individually, in cables which do not fulfill the requirements of pt. 1)
or
3) in groups, in a cable which does not fulfill the requirements of pt. 1), which
requires a system assessment
g) In systems exposed to lightning discharges, the use of external protective elements is
recommended.

3. Identification

a) Device name: Bottom Measurement Data Hub (DKDP)

Supplier/manufacturer name: Enterprise of Completion and Assembly of Automation
Systems „Carboautomatyka” S.A., tel. (32) 323-43-00; fax. (32) 323-43-23;
e-mail: carboautomatyka@carbo.com.pl; www.carbo.com.pl
b) Explanations of symbols:

DKDP / F* / L* / IO* / K* / W* / A**

where:
F* - number of DKDP_Fiber communication modules, e.g. F2
L* - number of DKDP_Line linear modules, e.g. L8
IO* - number of DKDP_4IN4OUT I / O modules, e.g. IO2
K* - type of connection chamber ( 1 : 160 x 360 x 91 mm or
2 : 250 x 400 x 161 mm)
W* - variant of the connection chamber (variants shown in
figures 107.188-M-0- ...)
A** - audiovisual alarm signals:
A00 – none,
A10 – LED,
A01 – BUZZER,
A11 – LED + BUZZER

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Example labeling:

DKDP / F1 / L7 / IO3 / K2 / W1 / A11 – DKDP equipped in a single FIBER module,

7 linear modules, 3 I/O modules, a large connection
chamber in the finishing variant no. 1 and BUZZER
and a LED for alarm signaling.

c) Labeling site: housing side.

4. Purpose

The DKDP Bottom Measurement Data Hub is performs continuous acquisition,

processing, visualization and archiving of signals from measurement sensors as well as binary
inputs built directly in the control panel.
The device is intended for installation in areas characterized by a risk of methane and /
or coal dust explosion and on the surface.
Communication with field devices (gas sensors, sensors of environmental parameters,
etc.) is carried out with one pair of copper wires using FSK or RS485 transmission.
DKDP data hubs can be combined to form a local security system (max 6 DKDP
hubs). The connection between successive DKDP hubs is carried out with the use of fiber
optics (star or daisy-chain topology).
The length of the measuring line from DKDP to terminal devices may not exceed 3 km.

NOTE!

* The DKDP Bottom Measurement Data Hub, also referred to as the data hub, or the
DKDP hub

5. Technical data

Table 1: Technical data

15V DC, 1.5A (Ui = 15.6V)

DKDP power supply
from an intrinsically safe buffer PSU
Min 4h
Supply life
from an intrinsically safe buffer PSU
Display LCD 320x240 Monochromatic
Keyboard Membrane, 64 keys or 6 buttons
Surface connection Fiber-optic, 1 or 2 single-mode threads
The maximum number of DKDP hubs Up to 8 pieces
in the system connected by fiber optics or RS485
Number of working modules in a
Up to 10 pieces
DKDP
Maximum number of terminal devices
Up to 4 pcs, depending on the type of device
connected to one telemetry line

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Telemetry line Baud rate Up to 6 kb/s FSK
Repetition time for a device on the Maximum of 0.25 s, with one terminal device
telemetry line on the telemetry line
Power consumption < 25 W
Length of the telemetry line < 3 km
Length of the two-state line < 3 km

Table 2 : Intrinsically safe DKDP parameters

DKDP_MASTER
BUS edge connector: 1-5 UI=15.5V
MONBUS connector 2-4, 3-4 U0=4.935V, I0=2.3mA, P0=11mW
DKDP_LINE
BUS edge connector: 1-5 UI=15.5V
U0=27.3V, I0=134mA P0=2.84W
Telemetry line L L- output
L0/R0=434mH/Ω
Analog 0-10V input
UI=14V, Ii=60mA
AVIN:1-AVIN:4
DKDP_LCDKEY
BUS edge connector: 1-5 UI=15.5V
DKDP_ARCHIVE
BUS edge connector: 1-4 UI=15.5V
DKDP_FIBER
BUS edge connector: 1-5 UI=15.5V
EXTBUS connector: 2-4,
U0=5.335V, I0=45mA, P0=0.24W, Ui=7V
EXTBUS: 2-5
DKDP_4IN4OUT
BUS edge connector: 1-5 UI=15.5V
OUT1: 1-2, OUT1: 3-4, OUT2: 1-2,
UI=60V, II=120mA, PI=330mW
OUT2: 3-4 connector
INPUTS1: 1-2,
INPUTS1: 3-4,
U0=7.875V, I0=13.5mA, P0=106mW
INPUTS2: 1-2,
INPUTS2: 3-4 connector

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Table 3 : Other technical data

Ingress protection IP65

Operating temperature -20C  Ta  +50C
Relative humidity max 95% without condensation
Dimensions (width x depth x height) 450 x 160 x 600 mm
Weight ~ 23 kg
Marking acc. to ATEX directive I M1 Ex ia Ma I
ATEX certificate number OBAC 18 ATEX 0110X

6. Design and principle of operation

The DKDP data hub consists of (Fig. 1):

 a plastic housing [1]
 a display [2]
 a keyboard [3]
 a connection chamber [4]
 built-in modules [5]

1 1
2
Archive

5
Master

In/Out
In/Out
Fiber

Line
Line
Line
Line
Line
Line
Line
Line
Line
3

Fig. 1 Bottom DKDP measurement data hub

Module description:
 The DKDP_MASTER module serves as the main DKDP controller and is
equipped with a rugged, powerful 32-bit RISC processor, a total of 192 kB RAM
and 8MB FLASH memory. This module is responsible for storing the current
configuration and querying all other modules to ensure proper operation of the
whole device.

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 The DKDP_ARCHIVE module is used for archiving the readings from sensors.
Records are saved on two micro SD cards. The module communicates with the
MASTER and the FIBER modules.
 DKDP_FIBER can be used to send information from DKDP to surfaces using a
fiber optic cable (directly or indirectly through another DKDP control unit in a
Daisy-Chain connection). The module also supports communication with other
DKDPs (for shorter distances up to 1 km) using a 3-wire RS-485 bus (EXT_BUS).
This connection is required when each DKDP has a separate optical fiber connected
to a computer, and there is a need to "exchange" alarms between them.
DKDP_FIBER is equipped with a powerful 32-bit processor, 1 MB of RAM, 8 MB
of FLASH memory, an ETHERNET controller, a fiber optic transceiver and
galvanically isolated RS485 port (EXT_BUS bus). DKDP can have 1 or 2 FIBER
modules, depending on the needs. If two modules are installed in DKDP, the
EXT_BUS bus connects them to each other.
Thanks to the FIBER module, communication between 8 DKDP hubs and a host
computer is possible. Connecting via an intrinsically safe optical fiber converter
directly to the computer as well as topologies of the star and Daisy-Chain is also
admitted.
Communication is carried out via a connectionless UDP protocol.
Communication using RS485 is carried out by means of a protocol in which one
DKDP is a master and initiates the transfer of data, and then sends their state in the
appropriate "time window". If there is no initiation of communication by the DKDP
master, the DKDP with the following number takes over its role.
At least one DKDP_FIBER module is necessary for DKDP to work.
 DKD_LCDKEY - LCD display and membrane keyboard controller module. It is
used to view the current state of the DKDP hub. Due to the fact that system
dispatchers are on the surface, this module does not support any system
configuration changes. It is rather used as an aid in diagnosing faults and installing
new sensors for underground service.
It is equipped with 128 kB of RAM and 8 MB of FLASH memory as well as a
monochromatic graphic display with a resolution of 320x240 points. Depending on
the version (\ A **), it can also be used to connect a light and sound alarm siren.
The module is necessary for starting and operating the DKDP.
 DKDP_LINE - line module. It is used to connect sensors to the DKDP hub.
Supported transmission methods include: FSK using a 2-wire line up to 2 km in
length or a 4-wire RS485 bus (power supply, ground, 2 RS485 wires).
The module has an insulated converter that increases the voltage on the line to
about 25 V, which ensures correct work of the sensors at the maximum length of
the tele-transmission line.
The line card can be used to connect up to 4 SC-xx series sensors, depending on the
type. In addition, the card has an RS485 transmission interface that allows the use
of sensors from other manufacturers compatible with this type of communication,
after appropriate changes in the software are made.
The card also has an analog voltage input, which is used to operate sensors with an
analogue 0.4-2V, 1-5V or 1-10V voltage output.

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The type of communication is selected by configuring the type of sensor on the
dispatching computer. The card also has the ability to control the output voltage - in
addition to the ability to enable / disable it, it can also be used to change its value in
256 steps, which translates into greater efficiency of the device with shorter
transmission lines.
 DKDP_4IN4OUT - Two -state input and output module, used to operate simple
contacts shorted / open, contacts with a serial diode and contacts with a resistor
divider. The module can be used to connect signals from external systems (e.g. 2
state output of the CPC-2 sensor) to the DKDP system, and to connect simple
contact devices, e.g. to control the closing of the dam 4 bi-state outputs allow
manual / automatic control of electricity at the bottom of the mine. It is then
necessary to connect the current switch with an intrinsically safe separator. Each
input / output can be stamped, i.e. its state can be controlled by a device on another
DKDP, and its state can affect another contacts within the DKDP system (up to 8
items).
Communication between the DKDP_ARCHIVE and DKDP_MASTER modules takes
place directly through the USART processors, as both printed circuit boards are installed
in the same double housing.
In addition, DKDP_ARCHIVE has an ARCHIVE_BUS bus - a bus connected to the
DKDP_FIBER module, which is used to download archive records bypassing the
DKDP_MASTER module, to reduce its load.
All modules are equipped with RGB LEDs to indicate the operating status, and executive
modules in the code counter, used to set the next number (0-9) to identify modules. In the
double housing of the DKDP_MASTER, DKDP_ARCHIVE modules, there is a code
controller, by means of which the DKDP number is set in the system.

7. Device installation

NOTE: The DKDP installation site should be chosen so as to exclude the adverse impact
of environmental factors such as dust, water, temperature and mechanical impact
(vibrations, shocks, impacts).
NOTE: The cables and wires to be connected to the DKDP must be inserted through the
glands into the connection chamber. Single wires should be terminated with
appropriate cable terminals and markers, and then screwed to the appropriate
connectors.
a) The device should be installed on slings supplied with DKDP in a position enabling the
cables to be inserted from the bottom of the device.
b) Open the front cover (door) of the DKDP junction box using the special key provided
with the DKDP to access connectors and cables.
c) Connect the power cable from the intrinsically safe power supply to the power connection
terminals located on the right side on the DIN rail.

d) Connect the intrinsically safe transmission lines to the appropriate connectors.

e) Connect the other circuits (transmission) - to external devices.

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8. Start-up
The device can be started after correct installation and after verifying if all connectons are
correct. To start the device:
a) Start the intrinsically safe buffer power supply.
b) Wait (about 1 minute) until the DKDP_MASTER module finishes the start-up procedure,
during which it recognizes and configures the remaining modules.
c) Accept the commissioning report that will appear on the display - from that moment on,
dispatchers can configure the operation of the actuators.
NOTE: The control panel software description, as well as the way it is configured and
operated, contain separate instructions.

9. Incorrect operation
In the event of failure whose symptoms match those described in Table 4, follow the
instructions contained therein.

Table 4 : Faults and how to proceed to eliminate them

No. Symptom of the fault Probable cause Procedure

No power on the DKDP unit - no
1. lights on the UPS and the front panel
of the KZ power supply panel are on
There is no report from the DKDP
start-up, the diode located on the
2.
DKDP_MASTER module does not
light up or lights up in red.
There is no report from the DKDP
start-up, the diode located on the
3.
DKDP_LCDKEY module does not
light or lights up in red.
The DKDP run report contains error
information about the
4. DKDP_ARCHIVE or DKDP_FIBER
modules
The dispatcher application cannot
5. communicate with DKDP
Power is not "reaching" the Check if the DKDP power cord is
DKDP unit live
An incorrectly configured or Make sure that the
damaged DKDP_MASTER DKDP_MASTER module is
module powered and properly plugged into
the rail.
Incorrectly connected or Make sure that the
broken DKDP_LCDKEY DKDP_LCDKEY module is
module connected to the DKDP_MASTER
module via the LCD bus.
Incorrectly connected or Make sure that the modules are
broken module needed for properly plugged into the bus and
DKDP DKDP_ARCHIVE or that the DKDP_FIBER module is
DKDP_FIBER to operate connected to DKDP_MASTER and
DPDP_ARCHIVE.
More than one DKDP has the Make sure that DKDP has the
same number encoded, fiber correct number encoded,
optic damaged. Check the optical fiber.

If the above mentioned diagnostic steps do not give a positive result or a different fault occurs,
please contact the manufacturer's service department or send the damaged module to the
service center.

10. Maintenance and repair instructions

11.1 Maintenance
Suitable personnel, trained by the manufacturer of the device, can be only admitted to
carry out any operation, maintenace and replacement of the DKDP data hub modules.
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Maintenance of the device consists in taking care of the proper working conditions of the
device, in accordance with the installation conditions and performing periodical checks
of the correct operation of the central unit. Suitable services should also inspect the
device from the outside and from the inside, control circuit connectors connecting the
outer compartment and the terminal modules.

NOTE! The manufacturer does not provide for repairs of modules by at the end user.
If any irregularities are found, the user should contact the service.
NOTE! The manufacturer allows the user to replace some elements, i.e.: Master modules,
Fiber, Line and 4In_4Out modules in the data hub housing;
11.2 Stop any SD card writing before disconnecting the power supply.
11.3 Replacing the DKDP_MASTER and DKDP_ARCHIVE modules
a) Open the DKDP housing.
b) Use the buttons to stop any writing on the memory cards.
c) Unplug all connected modules.
d) Pull the modules out of the rail with firm motion, pulling the lock out.
e) Encode the control panel number on the new module pair.
f) Optionally, move the SD card (to remove the card, it must be pressed gently).
g) Connect the DKDP_FIBER, DKDP_LCDKEY modules.
h) Slide the modules onto the rail with a firm motion.
i) Wait for the commissioning report and accept it.
j) The dispatcher must re-load the configuration of the actuators.
11.4 Replacing DKDP_FIBER modules
a) Open the DKDP housing.
b) Unplug all connected modules.
c) Pull the actuator out of the rail with firm motion, pulling the lock out.
d) On the new module, encode the number of the exchanged module.
e) Slide the new actuator onto the rail with a firm movement.
f) Connect the previously unplugged modules.
g) Close the control panel housing.

11.5 Replacing the DKDP_LINE / DKDP_4IN_4OUT actuators

NOTE! Actuators can be exchanged without switching off the power supply to the
control panel.
h) Open the DKDP housing.
i) Pull the actuator out of the rail with firm motion, pulling the lock out.
j) On the new module, encode the number of the exchanged module.
k) Slide the new actuator onto the rail with a firm movement.
l) Close the DKDP housing.

11.6 Connecting intrinsically safe lines to DKDP

The cables of intrinsically safe circuits should be inserted inside the DKDP connection
chamber through the glands from the bottom of the housing.
Cables should be unseated and run in such a way as to exclude the possibility of
accidental short-circuiting. The connection of the power supply and transmission lines
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to the terminals in the connection chamber should also make it impossible to
disconnect the wires. In no case should the wires of the power supply and transmission
lines intersect with the power supply cables.

12. Periodic inspections

Periodic inspection or maintenance of the DKDP bottom measurement data hub should be
carried out by representatives of the manufacturer or his authorized unit at least once a year.
During the review, the following activties are performed:
- review and cleaning of all elements included in the DKDP;
- control of technical condition and correctness of DKDP elements operation;
- control measurements of electrical parameters (power supply, output circuits, etc.);
- checking the functionality of the entire DKDP.
Each inspection should be closed with a report on the inspection carried out and the
measurements made.

13. Emergency procedure

After finding a faulty operation or failure of the DKDP data concentrator, please report the
fact to the DKDP manufacturer's 24-hour service.
The service team will consult on with the DKDP user and determine if it is necessary to come
to the site or if the fault can be removed by the user himself.
If the service team is needed on the site, it will arrive at the agreed time to the user to remedy
the failure.
Service is performed by:
The Department of Gasometric Devices
PKiMSA “Carboautomatyka” S.A. in Tychy
ul. Budowlanych 168
tel.: (32) 323 43 46 or 694 406 016
or another entity authorized by the manufacturer.

14. Instructions for the safe disposal of the device.

The crossed out bin symbol means that the product must not be disposed of in normal waste
containers. The used product should be sent to a collection point for electronic equipment.

15. Terms of use during the warranty period

Manufacturer's warranty coverage shall be maintained if the following requirements are
fulfilled:
 the recommendations contained in service manuals are complied with;
 markings (series number which identifies the product) are retained;
 product is used as intended.

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