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Siemens Energy & Automation, Inc. Installation and Service Instruction

SD39SAM-1 Rev: 6 September 2005

APACS+™

STANDARD ANALOG MODULE (SAM)

Trademarks ProcessSuite, QUADLOG, 4-mation, and APACS+ are trademarks of Siemens Energy & Automation, Inc.

Other names in this publication might be trademarks, the use of which by third parties for their own purposes may violate the rights of the registered holder.

Copyright Siemens Energy & Automation, Inc. 2005 All rights reserved

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent or registration of a utility model or design, are reserved. Siemens Energy & Automation, Inc. 1201 Sumneytown Pike P.O. Box 900 Spring House, PA 19477-0900

Disclaimer of Liability We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual is reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. ©Siemens Energy & Automation, Inc. 2005 Technical data subject to change.

SD39SAM-1 Contents

September 2005 i

Table of Contents

Section Title Page

1 Introduction....................................................................................................................1-1 1.1 Product Description ......................................................................................................1-2 1.2 Model Designation .......................................................................................................1-2 1.3 Specifications................................................................................................................1-4 1.3.1 Approvals ...............................................................................................................1-5 1.3.2 CSA Hazardous Location Precautions ...................................................................1-5 1.3.3 Electromagnetic Compatibility (EMC) ..................................................................1-7 1.4 Product Support ............................................................................................................1-8 1.4.1 Return of Equipment within North America........................................................1-10 1.4.2 Return of Equipment outside North America ......................................................1-10 1.5 Related Literature .......................................................................................................1-10

2 Installation......................................................................................................................2-1 2.1 Preparation....................................................................................................................2-1 2.2 I/O Wiring Considerations............................................................................................2-1 2.3 Hardware Identification................................................................................................2-3 2.4 SAM Handling..............................................................................................................2-3 2.5 SAM Termination Strip Installation .............................................................................2-4 2.6 SAM Marshalled Termination Assembly Installation ..................................................2-6 2.6.1 Marshalled Termination Assembly, DIN Rail Mount............................................2-6 2.6.2 Marshalled Termination Assembly Installation, Flat Surface Mount ..................2-10 2.7 I/O Cable Installation..................................................................................................2-11 2.8 SAM Installation.........................................................................................................2-15 2.8.1 Module and MODULRAC Mechanical Keying ..................................................2-15 2.8.1.1 Module (not factory keyed)........................................................................2-15 2.8.1.2 MODULRAC (or SIXRAC) ......................................................................2-15 2.8.2 Module Installation ..............................................................................................2-17 2.9 Electrical Installation..................................................................................................2-17 2.9.1 Field I/O Wiring Connections..............................................................................2-19 2.9.2 Unterminated I/O Cable .......................................................................................2-23

3 Circuit Description ........................................................................................................3-1 3.1 Isolated Power Supply ..................................................................................................3-2 3.2 IOBUS Modem.............................................................................................................3-2 3.3 V/I Conversion .............................................................................................................3-3 3.4 MUXs/Converters.........................................................................................................3-3 3.5 Rack-To-Rack Redundancy..........................................................................................3-3

4 Maintenance ...................................................................................................................4-1 4.1 Tool And Equipment Requirements .............................................................................4-1 4.2 Visual Inspection ..........................................................................................................4-1 4.3 Cleaning........................................................................................................................4-2 4.4 Calibration ....................................................................................................................4-2 4.5 Troubleshooting............................................................................................................4-3

Contents SD39SAM-1

ii September 2005

4.5.1 Error Codes and Messages .....................................................................................4-3 4.5.2 SAM Inputs and 4 to 20 mA Transmitter Signals..................................................4-4 4.6 SAM Removal/Replacement ........................................................................................4-4 4.6.1 Removal Procedure ................................................................................................4-4 4.6.2 Replacement Procedure..........................................................................................4-4 4.7 SAM Termination Strip Removal/Replacement...........................................................4-5 4.7.1 Removal Procedure ................................................................................................4-5 4.7.2 Replacement Procedure..........................................................................................4-5 4.8 SAM Marshalled Termination Assembly Removal/Replacement................................4-6 4.8.1 Removal Procedure ................................................................................................4-6 4.8.2 Replacement Procedure..........................................................................................4-6 4.9 SAM Interconnect I/O Cable Removal/Replacement...................................................4-6 4.9.1 Removal Procedure ................................................................................................4-6 4.9.2 Replacement Procedure..........................................................................................4-7 4.10 Spare And Replacement Parts ......................................................................................4-7

List of Tables

Table Title Page

Table 1–1 SAM Hardware ........................................................................................................................1-1

Table 1–2 SAM Accessories.....................................................................................................................1-1

Table 1–3 Standard Analog Module Specifications..................................................................................1-4

Table 1–4 Agency Approvals ...................................................................................................................1-5

Table 2–1 SAM Terminal Connections ..................................................................................................2-21

Table 2–2 Channel Number Vs Terminal Strip Number ........................................................................2-22

Table 2–3 Unterminated I/O Cable.........................................................................................................2-23

Table 4–1 LED Indications .......................................................................................................................4-3

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September 2005 iii

List of Illustrations

Figure Title Page

Figure 1–1 Standard Analog Module and Associated Assemblies ...........................................................1-3

Figure 2–1 Basic Local and Marshalled I/O Connections ........................................................................2-2

Figure 2–2 SAM Termination Strip Mounting and Interconnect I/O Cable Wiring.................................2-5

Figure 2–3 SAM Marshalled Termination Assembly...............................................................................2-7

Figure 2–4 Marshalling Termination Panel ..............................................................................................2-8

Figure 2–5 Marshalled Termination Assembly, Mounting and Removal, DIN Rail ................................2-9

Figure 2–6 Marshalled Termination Assembly, Mounting Ear Installation ...........................................2-11

Figure 2–7 Interconnect I/O Cable Assembly and Cable Keying...........................................................2-14

Figure 2–8 Module Keying Assignment and Installation .......................................................................2-16

Figure 2–9 Typical SAM I/O Connections .............................................................................................2-20

Figure 2–10 Signal I/O Cable Preparation..............................................................................................2-21

Figure 3–1 SAM Block Diagram..............................................................................................................3-2

Figure 3–2 Analog I/O Channel Schematic ..............................................................................................3-3

Significant Changes for Revision 6

Section Description

Preface (Conventions and Symbols)— new section

1.3.2 CSA Hazardous Location Precautions—WARNING alert added

1.4 Product Support—contact information updated

2.9 Electrical Installation—DANGER alert added

4 Maintenance—DANGER alert added

Contents SD39SAM-1

iv September 2005

PREFACE

Conventions and Symbols

The following symbols may appear in this manual and may be applied to the equipment. The reader should become familiar with the symbols and their meaning. Symbols are provided to quickly alert the user to safety related situations, issues, and text.

Symbol Meaning

DANGER

Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

Indicates a potential situation which, if not avoided, may result in an undesirable result or state.

Important Identifies an action that should be taken to avoid an undesirable result or state. Note Identifies additional information that should be read.

Electrical shock hazard. The included Warning text states that the danger of electrical shock is present.

Electrical shock hazard. Indicated that the danger of electrical shock is present.

Explosion hazard. Indicates that the danger of an explosion hazard exists.

Electrostatic discharge. The presence of this symbol indicates that electrostatic discharge can damage the electronic assembly.

SD39SAM-1 Contents

September 2005 v

Qualified Persons

The described equipment should be installed, configured, operated, and serviced only by qualified persons thoroughly familiar with this publication. The current version, in Portable Document Format (PDF), is available at http://sitescape.sea.siemens.com/.

For the purpose of this publication and product labels, a qualified person is one who is familiar with the installation, construction, and operation of the equipment, and the involved hazards. In addition, he or she has the following qualifications:

• Is trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in accordance with established safety practices.

• Is trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance with established safety practices.

• Is trained in rendering first aid.

Scope

This publication does not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to one of the support groups listed in the Product Support section of this manual.

The contents of this manual shall not become part of or modify any prior or existing agreement, commitment or relationship. The sales contract contains the entire obligation of Siemens. The warranty contained in the contract between the parties is the sole warranty of Siemens. Any statements continued herein do not create new warranties or modify the existing warranty.

General Warnings and Cautions

WARNING

This equipment contains hazardous voltages, and it has been certified for use in the hazardous locations specified on the product nameplate and in the Model Designation and Specifications section. Death, serious personal injury, or property damage can result if safety instructions are not followed. Only qualified personnel should work on or around this equipment after becoming thoroughly familiar with all warning, safety notices, and maintenance procedures contained herein. The successful and safe operation of this equipment is dependent upon proper handling, installation, operation, and maintenance.

The perfect and safe operation of the equipment is conditional upon proper transport, proper storage, installation and assembly, as well as, on careful operation and commissioning.

The equipment may be used only for the purposes specified in this publication.

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vi September 2005

CAUTION

Electrostatic discharge can damage or cause the failure of semiconductor devices such as integrated circuits and transistors. The symbol at right may appear on a circuit board or other electronic assembly to indicate that special handling precautions are needed.

• A properly grounded conductive wrist strap must be worn whenever an electronics module or circuit board is handled or touched. A service kit with a wrist strap and static dissipative mat is available from Siemens (PN15545-110). Equivalent kits are available from both mail order and local electronic supply companies.

• Electronic assemblies must be stored in anti-static protective bags when not installed in equipment.

DANGER

Electrical shock hazard Explosion hazard

Will cause death, serious injury or property damage

• Remove power from all wires and terminals and verify that there

are no hazardous voltages before working on equipment. • In potentially hazardous atmosphere, remove power from

equipment before connecting or disconnecting power, signal, or other circuit, or extracting/inserting module.

• Observe all pertinent regulations regarding installation in hazardous area.

• Ensure all devices are rated for hazardous (classified) locations.

SD39SAM-1 Introduction

September 2005 1-1

1 Introduction

This manual provides installation and service information for Standard Analog Module (SAM) hardware and accessories as listed in Tables 1-1 and 1-2 below.

Table 1–1 SAM Hardware

PART NUMBER DESCRIPTION PURPOSE

16133-71 Model 39SAMNAN Standard Analog Module 32 channel analog/discrete I/O module 16140-1 SAM Termination Strip (discontinued) Local termination of field I/O wiring 16169-1 SAM Marshalled Termination Assembly Remote termination of field I/O wiring 16137-122 Interconnect I/O Cable Assembly, 5.7 feet (1.75 m) 16137-114 Interconnect I/O Cable Assembly, 10 Ft. (3 m) 16137-115 Interconnect I/O Cable Assembly, 26 Ft. (8 m) 16137-116 Interconnect I/O Cable Assembly, 49 Ft. (15 m) 16137-117 Interconnect I/O Cable Assembly, 98 Ft. (30 m)

Connects SAM to SAM Marshalled Termination Assembly

16137-54 Unterminated I/O Cable Assembly, 10 Ft. (3 m) 16137-55 Unterminated I/O Cable Assembly, 26 Ft. (8 m) 16137-56 Unterminated I/O Cable Assembly, 49 Ft. (15 m)

16137-57 Unterminated I/O Cable Assembly, 98 Ft. (30 m)

1. Connects SAM to user-supplied field I/O terminations

2. Connects a SAM to a SAM Marshalled Termination Assembly when an Interconnect I/O Cable’s connector prevents conduit routing or other physical restrictions.

Table 1–2 SAM Accessories

PART NUMBER DESCRIPTION PURPOSE

16114-97 Marshalling Utility Panel (discontinued)

Contains mounted wire ducts and DIN rails for APACS Marshalled Termination Assemblies. Install in an APACS MODULPAC cabinet.

16114-12 Utility Panel (Blank) (discontinued)

For mounting hardware, wire ducts, and DIN rails. Install in an APACS MODULPAC cabinet. Has same dimensions as Marshalling Utility Panel.

16056-468 End Stop Kit End Stops prevent a SAM Marshalled Termination Assembly from sliding along the DIN rail on which it is mounted.

16056-562 Mounting Ear See Figure 2-6.

For flat surface mounting of a Marshalled Termination Assembly. Four ears are needed per Assembly.

Introduction SD39SAM-1

1-2 September 2005

This Instruction is divided into four major sections.

• Section 1, Introduction – Contains product description, model designation, specifications and product support details.

• Section 2, Installation – Describes installation preparation and mechanical and electrical installation.

• Section 3, Circuit Description – Contains a brief, block diagram level description of the module.

• Section 4, Maintenance – Describes preventive maintenance and troubleshooting procedures, assembly replacement procedures, and spare and replacement parts suggestions.

1.1 Product Description

The Standard Analog Module (SAM) is an APACS+™ I/O element capable of communicating with an APACS+ Control Module by way of the IOBUS. Figure 1-1 shows the SAM and associated assemblies and cables.

The SAM mounts in a single MODULRAC or SIXRAC slot. The module's bottom rear connector mates with either the SAM Termination Strip for local I/O connections or an Interconnect I/O Cable, that in turn connects to a SAM Marshalled Termination Assembly for remote I/O connections.

The SAM processes up to 32 channels of analog and/or discrete signals. Each SAM channel is separately configurable as an analog input or output or as a discrete input or output, using ProcessSuite® 4-mation™ Configuration Software. The SAM Termination Strip and SAM Marshalled Termination Assembly each have 32 terminal pairs plus terminals for cable shields.

Module status is indicated by two bezel LEDs labeled OK and ACTIVE.

A Local Termination Panel is needed to mount a SAM Termination Strip when local termination is employed. The Panel is not needed for marshalled (remote) terminations.

APACS architecture provides for rack-to-rack redundancy where the redundant rack completely duplicates the control and I/O modules of the primary rack. Both racks share common I/O terminations at the Marshalled Termination Assembly via their Interconnect I/O Cable Assemblies.

1.2 Model Designation 39SAM N A N Standard Analog Module (SAM)

Electrical Approvals: N = Not Required. Refer to SAM’s nameplate for current agency approvals.

Hardware Design Level

Software Revision Level


September 2005 1-3

Figure 1–1 Standard Analog Module and Associated Assemblies


1-4 September 2005

1.3 Specifications

Table 1–3 Standard Analog Module Specifications

SPECIFICATION DATA Module Weight 4.25 lbs. (1.9 kg.) Module Input Power Voltage Current, All Outputs @ 20mA Current, In Rush Current, Minimum Startup

24 VDC +/-10% 1.1 Ampere 2.5 Amperes Peak 0.3 Ampere

Channel Module Field Power Source Number of Channels Dielectric Strength

22.6 mA DC, current limited 32 (each configurable as input or output); all inputs/outputs referenced to field return common Tested to 3735 VDC for 2 seconds between all channels and ground

Analog Input Analog Update Rate, 32 Channels Input Range Standard Calibration Current Limiting Input Overvoltage (continuous) Calibration Accuracy Hardware Filter Cutoff Frequency

Less than 75 milliseconds 2.4 to 21.6 mA DC 4 to 20 mA DC 22.6 mA +/-30 VDC; externally limit current to 1A +/-0.1% of span over 4 to 20 mA 66 Hz, -40 dB/decade

Analog Output Output Range Standard Calibration Calibration Accuracy Load Capacity

0 to 22 mA DC 4 to 20 mA DC +/-0.1% of span over 4 to 20mA range 50 to 800 Ohms

Discrete Output* Output On (load less than 856 Ohms) Output On (load more than 856 Ohms) Output Off

23.6 mA Max., 22.7 mA Typ., 21.8 mA Min. 20.2V Min. 0.4 mA Max., 0.0 mA Min.

Discrete Input* Input Type Current Supplied Minimum On State Percentage Maximum Off State Percentage Default configuration > 8 mA Default configuration < 2 mA

Closure 10 mA 0 to 100% configurable, scaled from 0 to 10 mA 0 to 100% configurable, scaled from 0 to 10 mA Input On Input Off

Environment Operating Temperature Storage Temperature Operating Humidity Immunity, Electrostatic Discharge (ESD) Immunity, Radiated (RFI) Immunity, Power Lines and I/O, Fast Transients Immunity; Power Lines and Surges

-25° to 70°C (-13° to 158°F) -25° to 85°C (-13° to 185°F) 5 to 95% Non-Condensing EN61000-4-2; contact discharge, 8kV; air discharge, 15 kV EN61000-4-3; 10 V/m, 80-1000 MHz EN61000-4-4; Power, 4 kV; I/O, 2 kV EN61000-4-5, 2kV

* Available with Release 2.00 4-mation software.


September 2005 1-5

1.3.1 Approvals

A list of safety agency approvals is provided in Table 1-4. Refer to the module’s nameplate or contact Siemens for the most current information regarding SAM agency approvals.

Table 1–4 Agency Approvals

AGENCY APPROVAL DESCRIPTION

ABS1 ABS Type Approved.

CE CE marked as complying with the EMC Directive.

CSA CSA Certified for use in Class 1, Division 2, Groups A, B, C, and D hazardous locations with a temperature code of T4A @ 40 °C and T4 @ 70 °C.

FM FM Approved for use in Class 1, Division 2, Groups A, B, C, and D hazardous locations with a temperature code of T4A @ 40 °C and T4 @ 70 °C.

UL UL Listed in accordance with UL 508.

1 ABS compliance requires installing the SAM’s rack in an enclosure whose RF attenuation is 26 dB.

IMPORTANT

Before installing, applying power to, or servicing a SAM, see the module’s nameplate for electrical classification.

1.3.2 CSA Hazardous Location Precautions

This section provides CSA hazardous location precautions that should be observed by the user when installing or servicing the equipment described in this Instruction. These statements supplement those given in the preceding section.


1-6 September 2005

DANGER









September 2005 1-7

Precautions - English

For Class I, Division 1 and Class I, Division 2 hazardous locations:

• Use only factory-authorized replacement parts. Substituting components can impair equipment suitability for hazardous locations.

For Division 2 hazardous locations:

• When the equipment described in this Instruction is installed without safety barriers, the following precautions should be observed. Switch off electrical power at its source (located in a non-hazardous area) before connecting or disconnecting power, signal, or other wiring.

Précautions - Français

Emplacements dangereux de classe I, division 1 et classe I, division 2:

• Les pièces de rechange doivent être autorisées par l'usine. Les substitutions peuvent rendre cet appareil impropre à l'utilisation dans les emplacements dangereux.

Emplacement dangereux de division 2:

• Lorsque l'appareil décrit dans la notice ci-jointe est installé sans barrières de sécurité, on doit couper l'alimentation électrique a la source (hors de l'emplacement dangereux) avant d'effectuer les opérations suivantes branchment ou débranchement d'un circuit de puissance, de signalisation ou autre.

1.3.3 Electromagnetic Compatibility (EMC)

This product has been tested per the European Union’s EMC Directive. See the Declaration of Conformity at the back of this document. Refer to the following list for conditions for safe use.

• APACS/QUADLOG systems must use enclosures having sufficient RF attenuation.

• AC power input conductors to the enclosure must be filtered.

• MODULBUS (M-BUS) cables that enter or exit the enclosure must be filtered.

• The shields of all shielded cables that exit the enclosure must be connected to the enclosure.


1-8 September 2005

1.4 Product Support

Our Technical Support Centers (TSC) offer a variety of technical support services that are designed to assist you with Siemens products and systems. Our support engineers have experience with troubleshooting, development, system startup, and system test. They will help you to solve your issues in an efficient and professional manner.

Customers in North America can contact Siemens Technical Support Center at 1-800-333-7421, on the web at: http://support.automation.siemens.com, or by e-mail: [email protected]

Customers outside North America can contact their local Siemens subsidiary; addresses and telephone numbers are listed on the Internet at the web site: http://support.automation.siemens.com.

When contacting Siemens, customers will be asked to provide site-contact information (name, address, and phone number), the product involved and detailed information regarding the nature of the issue.

Product documentation is now located in the Library forum of the Process Automation User Connection at: http://sitescape.sea.siemens.com/. The Process Automation User Connection is a secure site. Registration is open to all verified users of Siemens process automation systems. If you are not already, and would like to become a member, please visit our Process Automation User Connection web page at: http://www.sea.siemens.com/process/support/papauc.html

Contained within the Process Automation User Connection is the APACS+/QUADLOG Secure Site at: http://sitescape.sea.siemens.com/forum/aca-1/dispatch.cgi/f.apacsquadlo forum. This site is only open to customers with an active service agreement. It contains all service manuals, service memos, service notes, configuration manuals, etc. for the APACS+ and QUADLOG family of products. If you are experiencing technical difficulties with the site, please contact SiteScape technical support at: toll free 1-877-234-1122 (US) or 1-513-336-1474.


September 2005 1-9

A&D Technical Support Worldwide, available 24 hours a day:

Beijing

Nürnberg

Johnson City

United States: Johnson City, TN Worldwide: Nürnberg Asia / Australia: Beijing Technical Support 24 hours a day, 365 days a year Phone:+49 (180) 5050-222 Fax:+49 (180) 5050-223 E-Mail: [email protected] GMT:+1:00

Technical Support and Authorization Local time: Monday to Friday 8:00 AM to 5:00 PM Telephone:+1 (423) 262 2522 or +1 (800) 333-7421 (USA only) Fax:+1 (423) 262 2289 Mail to: [email protected] GMT: -5:00

Authorization Local time: Monday to Friday 8:00 AM to 5:00 PM Phone: +49 (180) 5050-222 Fax: +49 (180) 5050-223 Mail to: [email protected] GMT: +1:00

Technical Support and Authorization Local time: Monday to Friday 8:00 AM to 5:00 PM Phone:+86 10 64 75 75 75 Fax:+86 10 64 74 74 74 Mail to:[email protected] GMT:+8:00

Automation and Drives Service and Support International http://www.siemens.com/automation/service&support

The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.


1-10 September 2005

1.4.1 Return of Equipment within North America

US Customers:

• Call the Repair Order PAS Inside Sales/Order Management Group at (215) 646-7400, ext 4RMA (4762) weekdays between 8:00 a.m. and 4:45 p.m. eastern time to obtain an RMA number. Mark the RMA number prominently on the outside of the shipment.

• When calling for an RMA number, provide the reason for the return. If returning equipment for repair, a detailed description of failure symptoms and system behavior will be requested. Supply a purchase order number for repairs. Follow the TSC specialist's recommendation for battery connection, if applicable.

• If applicable, you must supply a Material Safety Data Sheet (MSDS) with each item being returned if it was stored or used in a location where hazardous materials were present.

• Package items to be returned in their original shipping containers. Otherwise, package it for safe shipment or contact the factory for shipping recommendations. A module must be placed inside a static shielding bag to protect it from electrostatic discharge.

Canadian customers:

Contact Siemens Canada.

1.4.2 Return of Equipment outside North America

Contact your Siemens Representative.

1.5 Related Literature

The following literature should be available when performing the SAM installation.

• APACS+ MODULRAC Installation and Service Instruction (Document # SD39MODULRAC-1)

• APACS+ SIXRAC Installation and Service Instruction (Document # SD39SIXRAC-1)

• APACS MODULPAC 2000 Installation and Service Instruction (Document # SD39MODULPAC-2)

• Module Diagnostic Error Codes (CG39-19)

• APACS 4-mation Configuration Software Messages and Diagnostic Codes (CG39-21)

SD39SAM-1 Installation

September 2005 2-1

2 Installation

This section describes installation of the SAM and associated assemblies.

2.1 Preparation 1. Install the MODULRAC and the Local Termination Panel (for local termination only) in the cabinet

where SAMs are to be installed. SAMs should not be installed in the MODULRAC at this time, however, the MODULRAC slot numbers for SAM installation should be known.

2. If local I/O termination is employed, tag all I/O cables and route them into the cabinet. They should be ready for cable end preparation and connection to the SAM Termination Strips.

3. If remote termination is employed, tag all I/O cables and route them into the marshalling cabinet. They should be ready for cable end preparation and connection to the SAM Marshalled Termination Assemblies.

4. Also, route the SAM Interconnect I/O Cable (or Unterminated I/O Cable) between the marshalling cabinet and the cabinet containing the MODULRAC. See Figure 1-1; connector J1 will be installed in the MODULRAC and P2 will connect to the SAM Marshalled Termination Assembly in the marshalling cabinet.

2.2 I/O Wiring Considerations

Figure 2-1 shows typical local and marshalled I/O wiring. I/O connections between field devices and either local or marshalled terminations are wired with user-supplied cable. Typical cable has a jacket, shield and two insulated, twisted-pair conductors. Alternatively, individual insulated wires can be installed. Regardless, this cabling is referred to as “hook-up I/O cable”.

When marshalled termination is employed, an Interconnect I/O Cable Assembly connects the SAM Marshalled Termination Assembly to the MODULRAC and SAM. Interconnect I/O Cable Assembly part numbers and their standard lengths are listed in Section 1.0. An Interconnect I/O Cable length must be determined before proceeding with the installation of hardware assemblies.

Installation SD39SAM-1

2-2 September 2005

Figure 2–1 Basic Local and Marshalled I/O Connections


September 2005 2-3

2.3 Hardware Identification

A Standard Analog Module is identified by the letters “SAM” on the bezel and by two nameplate labels: a large label, shown below, located on the tracking plate (left side of module in Figure 1-1), and a small label inside the bezel compartment. Access to the bezel compartment is by loosening a captive screw in the hinged compartment cover.

Both labels contain the module model designation, part number, ROM version, and serial number. The larger label also shows the module current and voltage requirements. Space is provided for agency certifications and other important information.

MODEL 39SAMNAN AMPS x.xxx A P/N 16133-1 ROM VERSION x.xx VOLTS 24 VDC S/N xxxxxxxx

The SAM Termination Strip and SAM Marshalled Termination Assembly are identified by the following information silkscreened on the component side of the appropriate assembly:

TERMINATION STRIP

MARSHALLED TERMINATION ASSEMBLY

SAM SAM STANDARD STANDARD

ANALOG MODULE ANALOG MODULE SIEMENS ENERGY & AUTOMATION SIEMENS ENERGY & AUTOMATION

TERMINATION STRIP MARSHALLED TERMINATION PN 16140-1 ASSEMBLY

PN 16169-1

2.4 SAM Handling

The SAM is completely enclosed and may be safely handled without undertaking special ESD (electrostatic discharge) handling procedures. DO NOT touch the connector pins on the back of the module. Handle the module carefully and do not subject it to excessive shock or vibration.


2-4 September 2005

2.5 SAM Termination Strip Installation 1. Install a SAM Termination Strip at the MODULRAC (or SIXRAC) slot location of each SAM when

local I/O termination is used. As shown in Figure 2-2, a Local Termination Panel must be installed.

2. Consult user documentation and note the slot locations assigned to each SAM in each MODULRAC.

3. Note the following on a MODULRAC and Termination Strip:

a. On a MODULRAC, locate and identify the extruded spacer to which the lower edge of the back plane is mounted. The bottom of the extruded spacer is grooved. The top edge of a Termination Strip will rest in this groove.

b. Identify ten alignment pins located below the MODULRAC frame that span the width of the MODULRAC panel. One of these pins will engage a hole located on the Termination Strip above the MOORE logo. The left-most pin corresponds to MODULRAC slot #1.

c. The Termination Strip's captive mounting screws can be seen projecting from the bottom of the plastic extrusion panel.


September 2005 2-5

Figure 2–2 SAM Termination Strip Mounting and Interconnect I/O Cable Wiring


2-6 September 2005

4. Mount each Termination Strip at its assigned location as follows:

a. At the SAM slot, angle the top edge of the termination strip toward the back plane’s extruded spacer and insert the tip of the termination strip in the spacer's groove.

b. Slide the termination strip in the groove until it is vertically and horizontally aligned with the appropriate pin (slot #).

c. Carefully lower the termination strip and engage the pin with the extrusion and board pin mounting hole. Firmly push down to seat the strip on the pin. When the strip is properly seated, the pin will be flush with, or project slightly above the top surface of the termination strip.

d. Tighten the captive mounting screws that are automatically aligned with their respective panel mounting holes.

2.6 SAM Marshalled Termination Assembly Installation

Section 2.6.1 describes mounting a SAM Marshalled Termination Assembly on a DIN rail. Section 2.6.2 describes mounting a SAM Marshalled Termination Assembly on a flat surface.

2.6.1 Marshalled Termination Assembly, DIN Rail Mount

The SAM Marshalled Termination Assembly, shown in Figure 2-3, snaps onto a user-supplied DIN rail. The suggested types of DIN rails are:

• Preferred: Top hat profile EN 50 022-35mm X 7.5mm or EN 50 022- 35mm X 15mm

• Alternate: G-profile EN 50 035-G 32mm

Figure 2-4 shows a Marshalling Termination Panel with DIN rails and wire duct. Figure 2-5 shows installation and removal of a Marshalled Termination Assembly. Refer to the following to install a SAM Marshalled Termination Assembly to a DIN rail fastened to a Utility Panel, Marshalling Utility Panel, or user-fabricated panel.

• Utility or User Fabricated Panel - Mount user supplied DIN Rails and wire duct to the Panel.

1. Determine the mounting layout of Marshalled Termination Assemblies and wire duct. For the SAM, Termination Assembly and Utility Panel dimensions are provided in Figures 2-3 and 2-4.

NOTE

Termination Assembly dimensions for other I/O module types differ from the SAM’s. Consult a module’s Service Document for exact dimensions.

2. Drill and tap DIN rail and wire duct mounting holes in the Utility Panel.

3. Remove all burrs and metal debris and clean the panel.


September 2005 2-7

Figure 2–3 SAM Marshalled Termination Assembly


2-8 September 2005

Figure 2–4 Marshalling Termination Panel


September 2005 2-9

Figure 2–5 Marshalled Termination Assembly, Mounting and Removal, DIN Rail


2-10 September 2005

4. Mount the Marshalling Utility Panel, Utility Panel, or user fabricated panel in a MODULPAC marshalling cabinet or user supplied cabinet. Refer to Instruction SD39MODULPAC-1 for installation of the Utility Panel or Marshalling Utility Panel.

5. Retrieve the SAM Marshalled Termination Assembly to be mounted including a supplied bag of SAM labels (P/N 14205-682) and a Cable Keying Kit (P/N 16056-435). Temporarily set aside the Cable Keying Kit.

a. Consult user documentation and note the MODULRAC address number (1 to 16) and slot number

(1 to 10) assigned to the SAM, and if applicable the redundant SAM, that will be connected to this SAM Marshalled Termination Assembly. For rack-to-rack redundant SAMs connected to a MODULNET, the MODULNET node address must also be noted for each MODULRAC.

b. Retrieve a SAM label and record the noted MODULRAC and slot numbers on the label (see Figure 1-1). If MODULNET redundancy is applicable, record the appropriate node addresses on both SAM labels. Save the remaining labels for use in section 2.5.2.

6. Refer to Figure 1-1 and attach the SAM label adjacent to connector J1 as illustrated in the figure. If applicable, attach the redundant SAM label adjacent to J2.

7. Ensure that J1 and J2 are factory keyed according to the pattern shown in Figure 2-3.

NOTE Key the connector on the mating Interconnect I/O Cable, in section 2.7. This will prevent connection to the SAM Termination Assembly of an Interconnect I/O Cable from another type of APACS I/O module (e.g., SDM or VIM).

8. Refer to Figure 2-5 and mount the SAM Marshalled Termination Assembly to a DIN Rail.

2.6.2 Marshalled Termination Assembly Installation, Flat Surface Mount

To mount a SAM Marshalled Termination Assembly on a flat panel or bulkhead, remove the DIN rail mounting feet and install four mounting ears as described below. Four P/N 16056-562 mounting ears are needed per assembly as shown in Figure 2-6 (also see Accessories, section 1).

1. At one end of the Marshalled Termination Assembly, remove the three end cap securing screws from the card holder end cap. Remove and set aside the end cap.

2. Slide the DIN rail mounting feet from the grooves in the bottom of the Marshalled Termination Assembly card holder. Discard the mounting feet. Re-install the end cap.

3. Retrieve four mounting ears and insert them in the mounting holes provided in the end caps as illustrated in Figure 2-6.

4. Use the Marshalled Termination Assembly as a template to mark the location of the mounting ear holes on the surface of the panel. Mounting hardware is user-supplied but typically M4. After drilling or punching the holes, they should be threaded. See Figure 2-3 for assembly dimensions.


September 2005 2-11

Figure 2–6 Marshalled Termination Assembly, Mounting Ear Installation

2.7 I/O Cable Installation

An Interconnect I/O Cable (Figure 2-7) is used to connect each SAM to a SAM Marshalled Termination Assembly when remote I/O termination is employed. The cable-to-module connector (J1) is installed at the MODULRAC (or SIXRAC) slot location of a SAM.

It is assumed that as part of the site preparation procedure all tagged Interconnect I/O Cables have been routed and pulled into their respective cabinets and are ready for connection. SAM Marshalled Termination Assemblies should already be installed in the marshalling cabinet (see section 2.6) and be ready for cable connection. An Unterminated I/O Cable is installed similarly at the MODULRAC, however, terminations in the marshalling cabinet are user supplied.

1. Note the following on cable connector J1.

• The lower face of the molded connector has a “pin mounting hole” located above a captive mounting screw. This hole engages one of the MODULRAC Panel's ten alignment pins.


2-12 September 2005

• The top edge of J1 will rest in the groove of the backplane's extruded spacer as illustrated by a detail in Figure 2-2.

2. Consult user documentation and note the MODULNET node address (if applicable), MODULRAC address number (1 to 16) and slot number (1 to 10) assigned to the SAM. J1 will be mounted at this location.

3. Install J1 at its assigned location as follows:

a. Angle the top edge of the molded connector toward the back plane’s extruded spacer and insert its tip in the spacer's groove.

b. Slide the connector in the groove until it is vertically and horizontally aligned with the appropriate pin (slot #).

c. Carefully lower the molded connector and engage the alignment pin with the connector's pin mounting hole. Firmly push down to seat the connector on the pin. When the connector is properly seated, the pin will be flush with, or project slightly above the face surface of the connector.

d. Tighten the connector's captive mounting screw that is automatically aligned with its panel mounting hole.

e. Get two labels from the bag of SAM labels. Record on each label the appropriate numbers noted in the above step 2 (see Figure 1-1). Attach one label to J1; see Figure 1-1.

f. At the P2 end of the cable, attach the second label; see Figure 1-1.

4. Key cable connector P2.

a. Get the P/N 16056-435 Cable Keying Kit set aside in step 2 of section 2.5.1. The kit contains keying pins and an Instruction.

b. Refer to Figure 2-7 for the assigned keying pattern and install the pins in accordance with the supplied Instruction.

5. Connect the free end of the I/O Cable Assembly to the I/O termination assembly. Perform one of the following depending upon I/O Cable type.

• Interconnect I/O Cable Assembly (P2 installed)

Connect cable connector P2 (Figure 2-6) to the J1 connector on the Marshalled Termination Assembly (Figure 2-3). An alignment pin projecting from the face of P2 ensures correct mating. Press P2 firmly onto J1 and torque the securing screw on the top of P2's connector shell to 50 inch-pounds maximum.


September 2005 2-13

• Unterminated I/O Cable Assembly (P2 not installed)

Refer to section 2.9.2 for color code identification and function of each unterminated wire. Refer to user wiring diagrams to make the proper cable connections to the termination assembly.

6. For redundant SAMs, connect the redundant Interconnect I/O Cable's P2 connector to the B-side J2 connector of the Marshalled Termination Assembly as described in step 5 above.


2-14 September 2005

Figure 2–7 Interconnect I/O Cable Assembly and Cable Keying


September 2005 2-15

2.8 SAM Installation

Modules are shipped individually packaged in protective, sealed, static-shielding bags. Refer to section 2.4 for module handling considerations.

Each MODULRAC (or SIXRAC) slot and each module must be keyed to prevent accidental installation of a module into an incompatible slot which may impair system performance. Keying is highly recommended.

• Modules are keyed at the factory. The keying pattern is unique to each module type (e.g. ACM, SDM). See Figure 2-8 for the SAM keying pattern.

• A factory assembled MODULRAC is keyed at the factory. A user assembled MODULRAC is keyed by the user according to the module type assigned to each slot. This keying pattern complements the module's keying pattern. Stop plugs are supplied with the rack.

• When adding a module to a MODULRAC (or SIXRAC), be sure to key the rack slot.

Section 2.8.1 describes keying a module and a rack slot. Section 2.8.2 describes installing the module in its rack.

2.8.1 Module and MODULRAC Mechanical Keying

2.8.1.1 Module (not factory keyed) 1. Order Keying Kit P/N 16056-166. This kit contains keying pins for the module and stop plugs for the

MODULRAC (or SIXRAC).

2. Refer to Figure 2-8 and note the bezel keying pattern.

3. Thread the keying pins into the holes in the back of the module's bezel identified by the solid dots and carefully tighten the pins.

2.8.1.2 MODULRAC (or SIXRAC) 1. Get the Keying Kit supplied with the MODULRAC (or SIXRAC) or the Keying Kit in step 1 above.

2. Refer to Figure 2-8 and note the rack keying pattern. Also, locate the rack top and bottom rails.

3. Press the stop plugs into the holes identified by the solid dots.


2-16 September 2005

Figure 2–8 Module Keying Assignment and Installation


September 2005 2-17

2.8.2 Module Installation

Refer to Figure 2-8 and the following:

1. Refer to user documentation for correct module slot number.

2. Remove the SAM from its static shielding bag and ensure that the module is keyed. Also, check the MODULRAC slot to be sure it is keyed. Refer to section 2.8.1 to install keying.

3. Insert the module in the assigned MODULRAC slot. Firmly seat the module in the back plane connectors. A properly seated module will have the rear of its bezel flush against the front rails of the rack. A keyed module that is not matched to a slot will not engage the back plane connectors or seat flush against the front rails of the rack.

4. Pull open the bezel's pivoting top and bottom handles to expose the slotted captive mounting screws and secure the module to the top and bottom rails. Close the bezel’s handles when finished.

IMPORTANT

Do not use the captive mounting screws to seat the module. Damage to the bezel can result.

2.9 Electrical Installation

The following sections describe field I/O wiring connections to a SAM Termination Strip and to a SAM Marshalling Termination Assembly. It is assumed that tagged field I/O wires have been pulled into the cabinet and are ready for preparation and connection.

DANGER









2-18 September 2005

WARNING

Non-isolated analog input channels share a common ground. All I/O connected to this equipment must operate at extra low voltage or all equipment must be inaccessible to the user.

When stranded wire is used, prepare each wire end by stripping off its insulation and twisting the strands together. Do not solder the strands together.


September 2005 2-19

When connecting two or more wires to a single terminal on a SAM Termination Strip, join the wire ends together using a crimp-on connector as shown. Once joined, insert the connector’s pin into the wire slot of the terminal and tighten the terminal screw.

Wire 2

Wire 1

Crimp-onConnector

2.9.1 Field I/O Wiring Connections

A SAM Termination Strip and a SAM Marshalled Termination Assembly (Figure 1-1) support the connection of up to 32 configurable analog and/or discrete inputs or outputs. Be advised of the following when connecting these inputs and outputs to field wiring.

• Consult SAM configuration documentation and wiring diagrams for the assignment of each of the 32 channels. See Figure 2-9 for circuit wiring examples. The optimum grounding arrangement may be dependent on the equipment being connected and specific site conditions.

• Transmitters must be able to power up with a loop current limited to 22.5 mA, which is the SAM’s overload protection current limit.

• XTC™ Transmitters require a minimum network resistance of 250 Ω to use an MXC or Model 275 HART® Communicator. A package of 16 resistors (P/N 16056-229) is available.

• Prepare the input signal cable conductors and shield (see Figure 2-10). The cable should have twisted pairs of solid or stranded #22 or #20 AWG wire. Shielding is recommended.

• Wire each channel (each pair of terminals) as shown in Table 2-1. Table 2-2 correlates channel numbers and polarity with terminal block numbers.

• When installing rack-to-rack redundancy, wire field devices to the SAM Termination Strips or Marshalled Termination Assemblies at both involved racks.


2-20 September 2005

Figure 2–9 Typical SAM I/O Connections


September 2005 2-21

Figure 2–10 Signal I/O Cable Preparation

Table 2–1 SAM Terminal Connections

TERMINAL CHANNEL TYPE CONNECTION TYPE Analog In +24 VDC power for 2-wire transmitters

Analog Out Analog output control current (4 to 20 mA) Discrete In Contact type input (e.g. limit switch, relay)

CH +

Discrete Out Discrete output control current (22 mA typ.)

CH - All Types Field common return; all CH - terminals are tied together in the module

SHLD --- Signal cable shield ground connection


2-22 September 2005

Table 2–2 Channel Number Vs Terminal Strip Number

Channel Number, Polarity

Term. Strip

Number


Term. Strip

Number


Term. Strip

Number


Term. Strip

Number 1 (+)

1

9 (+)

17

17 (+)

33

25 (+)

49

1 (-)

2

9 (-)

18

17 (-)

34

25 (-)

50

2 (+)

3

10 (+)

19

18 (+)

35

26 (+)

51

2 (-)

4

10 (-)

20

18 (-)

36

26 (-)

52

3 (+)

5

11 (+)

21

19 (+)

37

27 (+)

53

3 (-)

6

11 (-)

22

19 (-)

38

27 (-)

54

4 (+)

7

12 (+)

23

20 (+)

39

28 (+)

55

4 (-)

8

12 (-)

24

20 (-)

40

28 (-)

56

5 (+)

9

13 (+)

25

21 (+)

41

29 (+)

57

5 (-)

10

13 (-)

26

21 (-)

42

29 (-)

58

6 (+)

11

14 (+)

27

22 (+)

43

30 (+)

59

6 (-)

12

14 (-)

28

22 (-)

44

30 (-)

60

7 (+)

13

15 (+)

29

23 (+)

45

31 (+)

61

7 (-)

14

15 (-)

30

23 (-)

46

31 (-)

62

8 (+)

15

16 (+)

31

24 (+)

47

32 (+)

63

8 (-)

16

16 (-)

32

24 (-)

48

32 (-)

64

Notes: (1) Table supports both the SAM Termination Strip and the SAM Marshalled Termination Assembly. (2) Wire polarities (+, -) and channel numbers are printed on the assembly. Terminal Strip numbers are molded into the assembly terminals. (3) Shield Terminals may be used as tie points for signal cable shield.


September 2005 2-23

2.9.2 Unterminated I/O Cable

The Unterminated I/O Cable does not have connector P2 installed. Wires are instead left for the user to terminate. Table 2-3 lists the wire color and identification information needed for termination. Refer to user wiring diagrams to make the proper cable connections to the termination assembly.

Table 2–3 Unterminated I/O Cable

J1, PIN

P2, PIN

WIRE STRIPE COLOR

WIRE I.D. J1, PIN

P2, PIN

WIRE STRIPE COLOR

WIRE I.D.

A2 75 WH/BLK CH 1 + E20 41 GRN/RED CH 20+ C2 74 WH/RED COM A22 16 GRN/BLUE CH 21+ E2 73 WH/BLUE CH 2 + C22 3 GRN/BRN COM A4 65 WH/GRN CH 3 + E22 17 GRN/OR CH 22+ C4 49 WH/BRN COM A24 6 GRN/YEL CH 23 + E4 64 WH/OR CH 4 + C24 19 GRN/VIO COM A6 91 WH/YEL CH 5 + E24 5 GRN/GRAY CH 24 + C6 104 WH/VIO COM A26 70 OR/WH CH 25 + E6 90 WH/GRAY CH 6 + C26 71 OR/BLK COM A8 100 RED/WH CH 7 + E26 72 OR/RED CH 26 + C8 101 RED/BLK COM A28 85 OR/BLUE CH 27 + E8 102 RED/BLUE CH 8 + C28 98 OR/GRN COM

A10 36 RED/GRN CH 9 + E28 84 OR/BRN CH 28 + C10 47 RED/BRN COM A30 96 OR/YEL CH 29 + E10 46 RED/OR CH 10 + C30 94 OR/VIO COM A12 11 RED/YEL CH 11 + E30 95 OR/GRAY CH 30 + C12 10 RED/VIO COM A32 92 YEL/WH CH 31 + E12 24 RED/GRAY CH 12 + C32 78 YEL/BLK COM A14 22 BLUE/WH CH 13 + E32 79 YEL/RED CH 32 + C14 8 BLUE/BLK COM Shield 1 Shield ------- E14 21 BLUE/RED CH 14 + A16 14 BLUE/GRN CH 15 + C16 27 BLUE/BRN COM E16 13 BLUE/OR CH 16+ A18 44 BLUE/YEL CH 17+ C18 43 BLUE/VIO COM E18 45 BLUE/GRAY CH 18+ A20 56 GRN/WH CH 19 + C20 57 GRN/BLK COM

SD39SAM-1 Circuit Description

September 2005 3-1

3 Circuit Description

The Standard Analog Module (SAM) receives signals from or sends signals to 2-wire field devices connected to 32 configurable I/O channels. Each channel can be configured as an analog input or output channel or as a discrete input or output channel.

The SAM digitizes analog/discrete input signals and transfers them to an APACS control module via IOBUS. Output signals are generated by the APACS control module and transferred to a SAM in digital form. The module converts these signals to equivalent analog signals and routes them to the appropriate terminal pairs.

Although the SAM does not directly support HART communications, it is compatible with HART devices that generate HART data in addition to their analog signals.

The Standard Analog Module consists of the following circuit elements:

• Central Processing Unit (CPU), Motorola 68302

• Memory (RAM and EPROM)

• IOBUS Interface

• 32 Standard Analog/Discrete Universal I/O Circuits

• Isolated Power Source

• LED Indicators

Circuit Description SD39SAM-1

3-2 September 2005

Figure 3-1 shows a simplified block diagram of the SAM. Figure 3-2 is a schematic of the circuitry in an analog/discrete I/O channel.

Figure 3–1 SAM Block Diagram

3.1 Isolated Power Supply

The on-board converter uses two switching regulators to produce a non-isolated +5V, isolated ±8V, and isolated +24V. Power for the MUX/CONVERTER section is supplied by dropping the ±8V unregulated and isolated supply to ±5V using linear regulators. An Optocoupler and FET are used to switch the isolated +24V supply to the V/I (Voltage-to-Current) Converter circuits. In a redundant operation, the stand-by SAM will have this (24V) supply switched off.

3.2 IOBUS Modem

The IOBUS element consists of an IOBUS Modem and dual IOBUS Line Drivers/ Receivers. The CPU supervises IOBUS communications through handshaking operations with the IOBUS Modem.

The IOBUS Modem performs the following:

• Converts received IOBUS data into a format for data processing.

• Converts digitized field data from the CPU into a format for transmission over the IOBUS to an APACS control module.

SD39SAM-1 Circuit Description

September 2005 3-3

3.3 V/I Conversion

There are 32 V/I circuits that condition each channel of the field connections. Each SAM channel provides an isolated and current limited power source to a 2-wire field device. A channel configured as an input accepts an analog or discrete signal from the field device powered by this module. An output channel provides a 4-20 mA analog signal or a 22 mA discrete signal to the field device.

Figure 3–2 Analog I/O Channel Schematic

3.4 MUXs/Converters

Channel inputs are read through five low leakage current analog Multiplexers (MUXs). The outputs of the MUXs are buffered and read by one input channel of an ADC (Analog-to-Digital Converter). Data from the ADC is transferred over a serial (SPI) interface to the CPU.

Channel outputs are generated by a DAC (Digital-to-Analog Converter) which receives data over the Serial Peripheral I interface (SPI) bus. The DAC output is multiplexed and sampled/held. The multiplexer reads the DAC voltage (sample/hold) reference through a divider network. This permits checks of DAC reference operation, conversion linearity, and multiplexer leakage current.

3.5 Rack-To-Rack Redundancy

A field device must be wired to the SAM Termination Strips or Marshalled Termination Assemblies at both involved racks when rack-to-rack redundancy is employed. The 24V field I/O power on the rack back planes is switched to apply power to the SAM in the active rack and remove power from the SAM in the inactive rack. When the racks are switched, the field device is continuously powered during the switchover. Analog output channels will see a doubling of current for 1 millisecond at switchover.

Circuit Description SD39SAM-1

3-4 September 2005

SD39SAM-1 Maintenance

September 2005 4-1

4 Maintenance

The Standard Analog Module and its associated assemblies require minimal maintenance. However, routine maintenance is recommended in the form of a visual inspection and a possible cleaning.

DANGER








4.1 Tool And Equipment Requirements

• Common electronic servicing hand tools

• Digital Multimeter (DMM)

• Ammeter with a ± 0.05% of reading accuracy and 1.0 µA resolution

4.2 Visual Inspection

The SAM and its associated assemblies should be subjected to a periodic visual inspection. The frequency of inspection will depend on the severity of the operating environment.

The primary aim of the inspection is to reveal any excessive accumulation of dust, dirt, or other foreign material adhering to the surfaces of transition board and protective covers of a SAM. Accumulation of dirt and dust prevents efficient heat dissipation and may cause module or system failure. A SAM installed in a cabinet complying with the NEMA 12/IP65 specification need not be inspected for cleanliness. Refer to section 4.3 for cleaning instructions.

An LED located on the SAM’s bezel indicates its status. Refer to section 4.5 for LED indications.

Maintenance SD39SAM-1

4-2 September 2005

4.3 Cleaning

Cleaning a SAM involves brushing or vacuuming the protective covers to restore cooling efficiency that may have been degraded by accumulated dust.

Cleaning a Termination Strip or SAM Marshalling Termination Assembly involves careful brushing and vacuuming to remove accumulated dust and dirt harboring chemical particulate that may accelerate terminal, switch, or connector contact corrosion.

4.4 Calibration

Each module is digitally calibrated at the factory and should not require field calibration verification or field calibration.


September 2005 4-3

4.5 Troubleshooting

4.5.1 Error Codes and Messages

Module status and errors are annunciated by two LEDs and displayed as error codes (4-mation Release 1.00) or error codes and messages (4-mation Release 2.00 and higher). LEDs are located on the bezel. Note LED states and refer to Table 4.1 for SAM status and to Module Diagnostic Error Codes (CG39-19) to determine the course of action.

For module related configuration messages that appear in 4-mation, refer to APACS 4-mation Configuration Software Messages and Diagnostic Codes (Document # CG39-21) for error reporting details.

Table 4–1 LED Indications

LED INDICATOR LED COLOR MODULE STATUS

OK

Solid Green Flashing Green/Black Flashing Red/Green Flashing Red/Black (1 per second) Flashing Red/Black (5 per second) Solid Red

Module OK; Configured with no faults Module Not Configured; No fault or failure Fault Detected; One or more channel specific errors, or a less severe board level error Failure Detected; Board level problem affecting more than one channel IOBUS Communication Error Module Fault, Severe; Replace module

ACTIVE

Solid Green OFF

Module in Control Redundant SAM in Standby Mode or off-line configuration of Module

Interconnect I/O Cable and Field Wiring and Devices

• Interconnect I/O cable pin assignments are given in Table 2-3 for troubleshooting a suspect cable.

• Check field wiring for proper connection, wire size, routing, and protection (e.g., conduit, wire duct).

• Check all field devices for proper operation.


4-4 September 2005

4.5.2 SAM Inputs and 4 to 20 mA Transmitter Signals

SAM inputs are designed with overload protection circuitry, which blocks current signals exceeding 22.5 mA. Blocked signals result in input failures from which the SAM can recover, provided its inputs are undamaged after overload conditions subside. Certain transmitters may generate signals greater than 22.5 mA when their measured quantities go off scale and readings become pegged.

Conditions causing over range readings may exist during process start-up, shutdown, or maintenance. Verify whether your process exhibits such behavior and, if the possibility of SAM input failures due to transmitter over ranging exists, try the following:

• Expand transmitter operating ranges so that they accommodate measurement swings beyond anticipated, normal operating values.

• Install signal conditioners or isolators on SAM input wiring to ensure that the 22.5 mA limit is never breached.

4.6 SAM Removal/Replacement

A module may be installed with power applied to the MODULRAC (or SIXRAC).

4.6.1 Removal Procedure

1. As shown in Figure 2-7, pull open the bezel's pivoted top and bottom handles to expose the module's slotted captive mounting screws. Loosen the screws.

2. Grasp the top and bottom handles and pull the module from the rack.

3. Place the module in a static shielding bag and package for return. Refer to section 4.11 for return instructions.

4.6.2 Replacement Procedure

1. Remove the replacement SAM from its protective bag. The module may be safely handled as the circuit card is shielded from access by protective covers. Retrieve and set aside the keying pin kit.

2. Key the replacement SAM as described in section 2.6.1.

3. Insert the SAM in its MODULRAC slot. Firmly seat the module in the back plane and termination board connectors. A properly seated module will have the rear of its bezel flush against the MODULRAC Housing rails.

4. A keyed module that is not matched to a slot will not engage the back plane or termination board connectors or seat flush against the MODULRAC (or SIXRAC) housing front rails.

5. As shown in Figure 2-7, pull open the bezel's pivoted top and bottom handles to expose the module's slotted captive mounting screws and secure the module to the top and bottom rails. Close the bezel's handles when finished.


September 2005 4-5

IMPORTANT

To avoid bezel damage, do not use the captive mounting screws to seat the module.

4.7 SAM Termination Strip Removal/Replacement


Refer to Figure 2-2 and the following removal procedure:

1. As necessary, take appropriate steps to shutdown the processes monitored or controlled by the field devices connected to the Termination Strip.

2. Remove the associated SAM from its slot in the MODULRAC. Place the SAM in a static shielded bag for protection.

3. Disconnect signal cables from the Termination Strip.

IMPORTANT

All signal cables should be labeled for correct reconnection.

4. Loosen the Termination Strip 's captive mounting screws. Gently lift the bottom of the Board in an arc until the board is free of its alignment pin located immediately above the "MOORE" logo. Pull the top of the Termination Strip from the grooved backplane spacer and lift it from the MODULRAC.


Refer to Figure 2-2 and the following replacement procedure:

1. Refer to section 2.4 and install the replacement Termination Strip.

2. Reconnect the signal cables.

3. Install the SAM. See section 4.6.


4-6 September 2005

4.8 SAM Marshalled Termination Assembly Removal/Replacement


Refer to Figure 2–2 and the following removal procedure:

1. As necessary, take appropriate steps to shutdown the processes monitored or controlled by the field devices connected to the Termination Assembly.

2. Remove the associated SAM from its slot in the MODULRAC. Place the SAM in a static shielded bag for protection.

3. Disconnect signal cables from the Termination Assembly.

IMPORTANT

All signal cables should be labeled for correct reconnection.

4. Refer to Figure 2-5. Press down on the Termination Assembly and carefully pull the Assembly away from the DIN rail.



1. Refer to section 2.5 and install the replacement Marshalled Termination Assembly.

2. Reconnect the signal cables.


4.9 SAM Interconnect I/O Cable Removal/Replacement


Refer to Figure 2-2 and the following removal procedure:

1. As necessary, take appropriate steps to shutdown the processes monitored or controlled by the field devices connected to the Termination Assembly.

2. If the Interconnect I/O Cable does not have connector P2 installed, remove the associated SAM from its slot in the MODULRAC (or SIXRAC). Place the SAM in a static shielded bag for protection.

3. Disconnect Interconnect I/O Cable connector P2 or individual connections from the Termination Assembly.


September 2005 4-7

IMPORTANT

Before disconnecting, label each connection to help ensure correct reconnection.

4. Loosen the Interconnect I/O Cable's captive mounting screws. Gently lift the bottom of the Cable in an arc until the Cable is free of its alignment pin. Pull the top of the Cable from the grooved backplane spacer and lift it from the MODULRAC.

5. Remove the Cable from the cable tray or other cable routing equipment.



1. Route the Interconnect I/O Cable between the MODULRAC (or SIXRAC) and marshalling cabinet.

2. Reconnect Cable as described in section 2.5.


4.10 Spare And Replacement Parts

One spare SAM should be stocked for every 1 to 10 in service. A spare module or replacement transition board can be ordered from one or the addresses in the Warranty statement or through a local Siemens Energy & Automation representative.

Part numbers are stated in section 1 and printed on most modules and associated hardware.

Several module main fuses should be stocked. Order 1.6A, 250 V, FastBlo (5 X 20 mm) fuses using Part # 7447-148.

When ordering, provide the model number, part number, and serial number from the module to be replaced or spared. A purchase order number should also be included for non-warranty purchases.

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