Emerson ROC827 manual

Flow Computer Division Form Number A6175 Part Number D301217X01 2 March 2006 ROC827 Remote Operations Controller Instruction Manual[...]

Issued Mar-06 ii Revision Tracking Sheet March 2006 This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover. Listed below is t[...]

Issued Mar-06 iii Contents Chapter 1 – General Information 1-1 1.1 Scope of Manual ............................................................................................................... 1 -1 1.2 Hardware ....................................................................................................................... ... 1-2 1.2.1 C[...]

Issued Mar-06 iv 2.8 Startup and Oper ation .................................................................................................... 2-19 2.8.1 Startup .............................................................................................................. 2-20 2.8.2 Operatio n .....................................................[...]

Issued Mar-06 v 5.9 Dial-up Modem Communications Mo dule ...................................................................... 5-12 5.10 Multi-Variable Sensor (MVS ) Interface Modules............................................................5-14 5.11 HART Interfac e Module .........................................................................[...]

Issued Mar-06 vi[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-1 Chapter 1 – General Information This manual focuses on the hardware aspects of the ROC827 Remote Operations Controller (the “ROC82 7”) and the ROC800-Series expanded backplanes (“EXPs”). For informati on about the software, refer to the ROCLINK ™ 800 Configuration Software [...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-2 Chapter 2 Installation and Use Provides information on installation, tools, wiring, mounting the ROC827, and other e ssential elements of the ROC827 and EXPs. Chapter 3 Power Connections Provides information on the Power Input modules available for the ROC8 27 and EXPs and provides wor[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-3 Figure 1-1. ROC827 Base Unit (without Expanded Backplane) The ROC827’s CPU contains the microprocessor, the firm ware, a connector to the backplane, three built-in comm unication ports, a Light- Emitting Diode (LED) low power wakeup button, a RESET button, the application license key[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-4 Figure 1-2 shows a typical expanded backplane (EXP) populated with a full complement of six I/O m odules. Each EXP is composed of the same plastic housing as the ROC827, contains six I/O slots, and has a powered backplane that easily attaches to the ROC827 and other EXPs. Figure 1-2. R[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-5 The ROC827 holds up to six communi cation ports (refer to Chapter 5, Communications ). Three communication ports are built-in:  Local Operator Interface (LOI) – Local Port EIA-232 (RS-232D).  Ethernet – Comm1 Port for use with the DS800 Development Suite Software.  EIA-232[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-6  Diagnostic monitoring.  Real-Time Clock.  Automatic self-tes ts.  Power saving modes.  Local Operator Interface (LO I) EIA-232 (RS-232D) Local Port.  EIA-232 (RS-232C) serial Comm2 port.  Ethernet Comm1 port. 1.2.2 Processor and Memory The ROC827 uses a 32-bit mic[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-7 1.2.4 Diagnostic Monitoring The ROC827 has diagnostic inputs in corporated into the circuitry for monitoring system integrity. Use ROCLINK 800 software to access the System Analog Inputs. Refer to Table 1-1. Table 1-1. System Analog Inputs System AI Point Number Function Normal Range 1[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-8 1.3 FCC Information This equipment complies with Part 68 of the FCC rules. Etched on the modem assembly is, among other in formation, the FCC certification number and Ringer Equivalence Number (REN) for this equi pment. If requested, this information must be provided to the telephone c[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-9  Historical Database.  Event and Alarm Log Databases.  Applications (PID, AGA, FST, and such).  Measurement Station Support.  Determining Task Execution.  Real-Time Clock.  Establishing and Managing Communications.  Self-Test Capability. The firmware makes exten[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-10 respective database point. These values are available for display and historical archiving. SRBX Spontaneous-Report-by-Exception (SRBX or RBX) communication allows the ROC827 to monitor for alarm conditions and, upon detecting an alarm, autom atically re ports the alarm to a host com [...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-11 The difference between 16-point and 8-point add ressing b ecomes critical when you have a host device reading data from specific TLPs. For example, under 16-point addressing, channe l 2 for a DI module in slot 2 is referenced by TLP 101,33,3. Under 8-poi nt addressing, channel 2 for a[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-12 The historical database is maintain ed in 11 segments. You can configure each segment in the database to archive selected points at s p ecified time intervals. The segments can continuous ly archive or can be turned on and off. You can distribute history points among history segments [...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-13 AGA 3 calculations conform to the methods described in American Gas Association Report No. 3, Orifice Me tering of Natural Gas and Other Related Hydrocarbon Fluids. Based on the second and third editions, the calculation method is 1992 AGA 3. The AGA 7 calculations conform to me thods[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-14 the user. The ROC827 wakes from Standby m ode when it needs to perform a task.  Sleep The ROC827 uses this mode if it detects a low battery voltage. The System AI Battery Poin t Number 1 measures the battery voltage and compares it to the LoLo Alarm lim it associated with th is poi[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-15 or symbols. Finally, argum ents provi de acces s to process I/O points and retrieve real-tim e values . A f unction may have zero, one, or two arguments. The FST Editor provides a workspace into which you can enter—for each FST— either a maximum of 500 lines or a maximum of 3000 b[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-16 system keeps time-stamped m inute, peri odic, and daily data values as well as yesterday’s and today’s dail y minimum and maximum values. You can collect history values fr om the ROC827 using ROCLINK 800 or another third-party host system. You can view history directly from the RO[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-17 DS800 Development Suite software allows programming in all five of the IEC 61131-3 languages:  Ladder Logic Diagrams (LD).  Sequential Function Chart (SFC).  Function Block Diagram (FBD).  Structured Text (ST).  Instruction List (IL). A Flow Chart language provides a si[...]

ROC827 Instruction Manual Issued Mar-06 General Information 1-18 1.8 Related Specification Sheets For technical details on the ROC 827 and the ROC800-Series expanded backplane, refer to the specificati on sheet 6:ROC827. The most current version of this specifica tion sheet is available at www.EmersonProcess.com/flow . Note : Since the expanded bac[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-1 Chapter 2 – Inst allation and Use This chapter describes the ROC 827 housing (case), its backplane (electronic connection board at the back of the hous ing), the ROC800- Series CPU (central processing uni t), and the ROC800-Series Expanded Backplane (EXP). This chapter provid es a d[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-2 ground conditions, climate, and acces sibility), th is document only provides generalized guidelines. 2.1.1 Environmental Requirements Always install the ROC827 in a use r-supplied enclosure, as the ROC827 requires protection from direct exposure to rain, snow, ice, blowing dust or de[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-3  Choose a location for th e ROC827 away from heavy traffic areas to reduce the risk of being damaged by vehicles. However, provide adequate vehicle access to aid m onitoring and maintenance.  The site must comply with class lim its of Part 15 of the FCC rules. Operation is subje[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-4 2.1.4 Power Installation Requirements Be sure to route power away from hazardous areas, as well as sensitive monitoring and radio equipment. Lo cal and company codes generally provide guidelines for installations. Adhere rigorously to all local and National Electrical Code (NEC) requi[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-5 Install a surge protection device at the service disconnect on DC voltage source systems to protect against li ghtning and power surges for the installed equipment. All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as m easured with a ground syste[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-6 2.3.1 Removing and Replacing End Caps Normal use and maintenance of the ROC827 does not typically require you to remove the end caps on the h ousing. Follow these procedures in case removal is necessary. To remove the end caps: 1. Place the tip of a flat-blade screwdri ver in to the t[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-7 2.3.3 Removing and Installing Module Covers Before you insert an I/O or communi cations module, remove the module cover over the empty module slots in which you intend to install the modules. Although you are not required to remove the power to the ROC827 to perform this procedure, ca[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-8 Figure 2-1. Side View of the ROC827 Figure 2-2. Bottom View of the ROC827 Note : The distance from the mounting pane l to the front of the ROC827 is 174mm (6.85”). If you mount the ROC827 inside an enclosure and want to connect a cable to the LOI or Ethernet port, ensure ade quate c[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-9 Figure 2-3. Back View of the ROC827 2.4.1 Installing the DIN Rail To install the ROC827 using the 35 x 7.5 mm DIN rails: 1. Mount the lower DIN rail ont o the enclosure panel. 2. Snap the upper DIN rail into the ROC827 upper DIN rail mounting blocks. 3. Place the ROC827 onto the lower[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-10  ROC827 and one EXP: Place catc hes on ROC827 and EXP.  ROC827 and two EXPs: Place catches on ROC827 and second EXP.  ROC827 and three EXPs: Place catch es on ROC827 and third EXP.  ROC827 and four EXPs: Place cat ches on ROC827 and second and fourth EXP. 2.4.3 Removing t[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-11 Removing the backplane from the housing is not recommended, as there are no field serviceable parts. If the backplane requires maintenance, please contact your local sales representative. 2.5.1 Attaching an Expandable Backplane To attach an EXP to an existing ROC 827 base unit or to [...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-12 2.5.2 Removing an Expandable Backplane Note : Before you remove an EXP, you must power down the ROC827, disconnect all wiring from all modules, and remove the entire unit from the DIN rail. Once the entire ROC827 is free of the DIN rail, you can detach an individual EXP. To remove an[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-13 4. Using a flat-bladed screwdriver, gen tly pry the plastic locking clips at the upper and lower back edge of the EXP housing away from their securing tabs. Note : Applying too much pressure breaks the plastic hooks. 5. Once you free the plastic locking clips from their securing tabs[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-14 Figure 2-6. CPU Front View Figure 2-7. CPU Connectors LED Button RESET Button LOI – EIA-232 (RS-232D) x STATUS LED x LICENSE KEYS x ETHERNET x EIA-232 (RS-232C) Battery LED Button License Key (at P4) RESET Button Boot ROM License Key (at P6) Securing Screw Securing Screw[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-15 Table 2-1. CPU Connector Locations CPU Number Definitions J4 Not Used P2 LOI Port RJ-45 P3 Ethernet RJ-45 P4 License Key Terminal P6 License Key Terminal SW1 LED Button SW2 RESET Button The CPU contains a microprocessor s upervisory circuit. This device monitors the battery voltage, [...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-16 button, LEDs light and stay lit again for five minutes. By entering a 0 (zero) setting, the LED always stays lit. 2.6.1 Removing the CPU Module To remove the CPU module: Caution Failure to exercise proper electrosta tic discharge precautions (suc h as wearing a grounded wrist stra p)[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-17 4. Tighten the two screws on the facepla te of the CPU m odule firmly (see Figure 2-5). 5. Replace the wire channel cover. 6. Review “Restarting the ROC827” in Chapter 6, Troubleshooting . 7. Return power to the ROC827 unit. 2.7 License Keys License keys with valid license codes [...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-18 2.7.1 Installing a License Key To install a license key: Caution Failure to exercise proper electrosta tic discharge precautions (suc h as wearing a grounded wrist stra p) may reset the processor or da mage electronic components, resulting in interrupted o peratio ns. When working on[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-19 2.7.2 Removing a License Key To remove a license key: Caution Failure to exercise proper electrosta tic discharge precautions (suc h as wearing a grounded wrist stra p) may reset the processor or da mage electronic components, resulting in interrupted o peratio ns. When working on un[...]

ROC827 Instruction Manual Issued Mar-06 Installation and Use 2-20 Caution Check the input po wer polarity before connecting po wer to the ROC827. Incorrect polarity can damage the ROC8 27. When working on units located in a hazardous ar ea ( where explosive gases may be present), make sure the area is in a non-h azardous state before performing pro[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-1 Chapter 3 – Power Connections This chapter discusses the Power Input modules. It describes the modules, explains how to install and wire th em, and provides worksheets to help you determine—and tune—the power requirements for the I/O and communications modules you can instal l in t[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-2 the ROC800-Series modules via the backplane. The ROC827 requires 11.25 to 14.25 Volts dc for proper operation. Figure 3-1. 12 Volt dc Power Input Module The CHG+ and CHG– terminals comprise an Analog Input channel that allows you to monitor an external vol tage between 0 to 18 volts dc[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-3 Table 3-1. 12 Volt dc Power Input Terminal Block Connections Terminal Blocks Definition Volts DC BAT+ and BAT– Accepts 12 Volts dc nomin al from an AC/DC converter or other 12 Volts dc supply.  Absolute Maximum: 11.25 to 16 Volts dc  Recommended Operating Range: 11.25 to 14.25 Vo[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-4 Figure 3-2 . 24 Volt dc Power Input Module Table 3-3. 24 Volt dc Power Input Terminal Block Connections Terminal Blocks Definition Volts DC + and – Accepts 24 Volts dc nomina l from an AC/DC converter or other 24 Volts dc supply. 18 to 30 Volts dc AUX+ and AUX– Supplies reverse polar[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-5 For the 24 volt Power Input module (PM-24), the AUX voltage is always 12 Volts dc minus ~0.7 Volts. AUX+ / AUX– is internally current-limited by a 0.5 Amp Positive Temperature Coefficient (PTC). If you need to cycle power to the radi o or other device to reduce the load on the power so[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-6 3.1.4 Switched Auxiliary Ou tput (AUXSW+ and AUXSW–) The AUX SW + and AUX SW – term inals on the 12 volt dc Power Input module (PM-12) provide switched powe r for external devices, such as radios. AUX SW + is current-limited for protection of the power input and the external device v[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-7 3.2 Determining Power Consumption Determining the power consumption requirem ents for a ROC827 configuration involves th e following steps: 1. Determine your ideal ROC827 configuration, which includes identifying all modules, device re lays, m eters, solenoids, radios, transmitters, and [...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-8 General Calculation Process To calculate the power the ROC827 requires: 1. Determine the kind and number of communication modules and the kind and number of expanded backplanes you are implementing. Enter those values in the Quantity Used colum n of Table 3-5. 2. Multiply the P Typical v[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-9 10. Add the values for the Power System Safety Factor (0.25) to the Total for ROC827 Base Unit, All Modules , and Other Devices to determine the total estimated power consum ption for the configured ROC827 system.[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-10 Table 3-5. Estimated Power Consumption Power Consumption (mW) Device Description P TYPICAL Quantity Used Sub-Total (mW) CPU and ROC827 Ba ckpl ane Power Input Module PM-12 110 mA @ 12 volts dc 1320 mW Power Input Module PM-24 55 mA @ 24 volts dc 1320 mW Per Active LED – Maximum 10 1.5[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-11 3.2.1 Tuning the Configuration The PM-12 Power Input module can supply a m aximum of 36 W (36000 mW) to the backplane, which includes the +T overhead . The PM-24, when operating between –40 ° C to 55 ° C, can supply a maximum of 30 W (30000 mW) to the backplane. Across its entire op[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-12 Table 3-6. Power Consumption of the Analog Input Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) ANALOG INPUT AI Module Base 84 mA @ 12 volts dc 1008 mW Jumper set for +T @ 12 volts dc Channel 1 Channel’s mA current draw from +T [...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-13 Table 3-7. Power Consumption of the Analog Output Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) AO Module Base 100 mA @ 12 volts dc 1200 mW Jumper set for +T @ 12 volts dc Channel 1 Channel’s mA current draw from +T * 1.25 * 12[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-14 Table 3-8. Power Consumption of the Discrete Input Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) DI Module Base 19 mA @ 12 volts dc No Channels Acti ve 228 m W Channel 1 3.2 mA @ 12 volts dc 38.4 mW Channel 2 3.2 mA @ 12 volts dc[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-15 Table 3-9. Power Consumption of the Discrete Output Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) DO Module 20 mA @ 12 volts dc No Channels Acti ve 240 m W Channel 1 1.5 mA 18 mW Channel 2 1.5 mA 18 mW Channel 3 1.5 mA 18 mW Chan[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-16 Table 3-10. Power Consumption of th e Discrete Output Relay Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) DOR Module 6.8 mA @ 12 volts dc No Channels Active 81.6 mW Channel 1 150 mA for 1 0 mSec during transition 1800 mW for 10 m[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-17 Table 3-11. Power Consumption of the High and Low Speed Pulse Input Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) PI Module 21 mA @ 12 volts dc No Channels Acti ve 252 mW Channel 1 7.4 mA 88.8 mW Channel 2 7.4 mA 88.8 mW Per Acti[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-18 Table 3-12. Power Consumption of the MVS Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) MVS Module 112 mA @ 12 volts dc 1344 mW Per Active LED – Maximum 2 1.5 mA 18 mW Power provided by the module for the MVS sensors 1.25 * Meas[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-19 Table 3-13. Power Consumption of the RTD Modules Power Consumption (mW) I/O Module Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) RTD Module 65 mA @ 13.25 volts dc 1 Table Total Duty Cycle An RTD has no associated duty cycle. Consequently, always set “1” as the duty c[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-20 Table 3-16. Power Consump tion of Other Devices Power Consumption (mW) Other Device Description P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) Total Although Tables 3-5 and Tables 3-6 th rough 3-15 take into account the power the ROC827 supplies to its conn ected devices, be sure to [...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-21 3.4 Installing a Power Input Module To install the Power Input module: Caution Failure to exercise proper electrosta tic discharge precautions, such as wearing a grounded wrist stra p may reset the processor or damage electronic components, resulting in interrupted o peratio ns. When wo[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-22 The ROC827 should have a minimum of bare wire exposed to prevent short circuits. Allow some slack when making connections to prevent strain. 3.5.1 Wiring the DC Power Input Module Use 12 American Wire Gauge (AWG) wire or smaller for all power wiring. It is important to use good wi ring [...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-23 – CHG+ – BAT+ 5 Amp Fuse + – + – + – + – – Batteri es 809CHG.DSF Solar Regulator So lar Pane l + – 5 Amp F use Power Supply Terminal Block Figure 3-6. 12 Volt dc Power Suppl y and CHG+ and CHG– Wiring 10. Replace all other power sources (if necessary) to the ROC827. 11[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-24 Battery Reserve Battery reserve is the amount of tim e that the batteries can provide power without discharging below 20% of their total ou tput capacity. The battery reserve should be a mini mum of five days, with ten days of reserve preferred. Add 24 hours of reserve capacity to allow[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-25 3.5.3 Replacing the Internal Battery The internal Sanyo 3 volt CR2430 lithium backup battery located on the CPU provides backup of the data and the Real-Time Clock when the main power is not connected. The battery has a one-year m inimum backup life while the battery is insta lled and n[...]

ROC827 Instruction Manual Issued Mar-06 Power Connections 3-26 7. Insert a plastic screwdriver behi nd the battery and gently push the battery out of the battery holder. Note how the battery is oriented : the negative side of the battery (– ) is placed again st the CPU and the positive (+) towards the + label on th e battery holder. 8. Insert the[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-1 Chapter 4 – Input/Output Modules This chapter describes the Input/Out put (I/O) modules used with the ROC827 and expandable backplanes and contains information on installing, wiring, and rem oving the I/O modules. In This Chapter 4.1 I/O Module Overview .............................[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-2 DOC0513A Front View Side View Figure 4-1. Typical I/O Module Figure 4-2. Optional I/O Module Lo cations (ROC827 with one EXP) I/O modules for the ROC827 include:  Analog Input (AI) modules that provide the ability to monitor various analog field values.  Discrete Input (DI) and [...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-3  Analog Output (AO), Discrete Outp ut (DO), and Discrete Output Relay (DOR) modules that provide the ability to manage various control devices.  The RTD Input and Thermocouple Input (T/C) modules that provide the ability to monitor various an alog tem perature field values.  [...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-4 default configurations. Refer to the ROCLINK 800 Configuration Software User Manual (Form A6121). 4.2.1 Installing an I/O Module To install an I/O module in ei ther the ROC827 or the EXP: 1. Remove the wire channel cover. Note : Leaving the wire channel cover in place can prevent the [...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-5 Figure 4-3. Installing an I/O Module 4. Tighten the captive screws on the front of the module. 5. Wire the I/O module (ref er to “Wiring I/O Modules”). 6. Replace the wire channel cover. Caution Never connect the shea th surrounding shielded wiring to a signal ground terminal or t[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-6 6. Replace the wire channel cover. 4.2.3 Wiring I/O Modules All modules have removable term inal blocks for convenient wiring and servicing. The terminal blocks can accommodate a wide range of wire gauges (12 AWG or smaller). Caution Failure to exercise proper electrosta tic discharge[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-7 Figure 4-4. Analog Input Jumper J4 – Set to +24V 1-5 VOLT DEVICE EXTERNALLY POWERED + - 1-5 VOLT DEVICE EXTERNALLY POWERED + - ROC809 POWERED CURRENT LOOP DEVICE 4-20mA - + OUT SIGNAL COM IN DOC0506A Figure 4-5. Analog Input Module Field Wiring Note : All I/O modules are isolated on[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-8 4.4 Analog Output Modules The 16-bit Analog Output (AO) module has four channels that provide a current output for powering analog devices. Analog Outputs are analog signals the ROC827 generates to regul ate equipment, such as control valves or any device requ iring analog control. Ea[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-9 Figure 4-7. Analog Output Module Field Wiring Note : All I/O modules are isolated on th e field side. Be aware that you can induce ground loops by tying commons from various modules together. 4.5 Discrete Input Modules The eight-channel Discrete Input (DI) modules monitor the status o[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-10 The left side of Figure 4-8 displays the internal circuitry while the r ight side displays possible field wiring. Note : All I/O modules are isolated on th e field side. Be aware that you can induce ground loops by tying commons from various modules together. + - DRY CONTACT ROC800 P[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-11 Caution The Discrete Output module only operates with non-po wered discrete devices, such as relay coils or solid-state s witch inputs. Using the module with powered devices may cause improper oper ation or dam age. DO modules draw power for the active circuitry from the backplane, a[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-12 Note : The Discrete Output Relay modul e operates only with discrete devices having their own power source. When a request is made to change the state of a DOR, the request is immediately sent to the DOR module. There is no scan time associated with a DOR. Under normal operating cond[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-13 The PI is most commonly used to interface to relays or open collector/open drain type solid-state devices. The Pulse Input can be used to interface to either self-power ed or ROC827-powered devices. The high speed input supports signals up to 12 kHz while the low speed input is used [...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-14 + - OPEN DRAIN TY PE OR OPEN COLLEC TOR DEVICE EXTERNALLY POW ERED + - CONTACT-CLOSUR E DEVI CE EXTERNALLY POWERE D 12KHz PI FILTER & LEVEL DETECTION 12KHz PI FILTER & LEVEL DETECTION DOC0510A Figure 4-12. Externally Powered Pulse Input Module Field Wiring + - 12KHz PI FILTER[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-15 The RTD input module works by supplyi ng a small consistent current to the RTD probe and measuring the vol tage drop across it. Based on the voltage curve of the RTD, the ROC 827 firmware converts the signal to temperature. The RTD input module monitors the te mperature signal from a[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-16 Note : All I/O modules are isolated on th e field side. Be aware that you can induce ground loops by tying commons from various modules together. Figure 4-14. RTD Sensor Wiring Terminal Connections Figure 4-14 and Table 4-2 display the connections at the RTD terminals for the various[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-17 by the junction between the different metal of the T/C wiring and the T/C module’s terminal blocks. Note : The use of dissimilar metals is not supported. It will not provide the correct results, as CJC is applied at the module level. Thermocouples are self-powered and require no ex[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-18 J OR K THERM OCOUPLE UNGROUNDED SHEATH + - DOC0512B Figure 4-15. Type J and K Thermocouple Wiring Be sure to use the correct type of thermocouple wire to connect the thermocouple to the ROC827. Minim ize connections and make sure connections are tight. If you use any dissimilar metal[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-19 Noise Susceptibility Millivolt signals are very small and are very susceptib le to noise. Noise from stray electrical and ma gnetic fields can generate voltage signals higher than the millivolt lev els generated from a thermocouple. The T/C modules can reject common m ode noise (sign[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-20 Note : Only ungrounded probes are supported. It is highly recommended that you use sheathed probes. Use an ungrounded junction for measurements in corrosive environm ents where it is desirable to have the ther mocouple electronically isolated from and shielded by the sheath. The weld[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-21 4.11 Related Specification Sheets Refer to the following specifi cation sheets (available at www.EmersonProcess.com/flow ) for additional and most-current information on each of the I/O modules. Table 4-3. I/O Module Specification Sheets Name Form Number Part Number AI and AO Modules[...]

ROC827 Instruction Manual Issued Mar-06 Input/Output Modules 4-22[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-1 Chapter 5 – Communications This section describes the built-i n communications and the optional communication modules used with the ROC827. In This Chapter 5.1 Communications Ports an d Modules Ov erview ....................................... 5-1 5.2 Installing Communi cation Modul es ..[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-2 Figure 5-1. Communication Ports Table 5-2. Communication LED Indicator Definitions Signals Action CTS Clear To Send indicates the modem is ready to send. CD Data Carrier Detect (DCD) indicates a valid carrier signal tone detected. DSR Data Set Ready for ring indicator communication sign al.[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-3 5.2 Installing Communication Modules All communication modules install into the ROC827 in the sam e way. You can install or remove communi cation modules while the ROC827 is powered up (hot-swappable), you can install modules directly into unused module slots 1, 2, or 3 (hot-pluggable), and[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-4  If there is a module currently in the slot , unscrew the captive screws and remove that module (refer to “Rem oving a Communications Module”).  If the slot is currently empty, remove the m odule cover. 3. Insert the new module through the m odule slot on the front of the ROC827 h[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-5 6. Replace the wire channel cover. 5.4 Wiring Communications Modules Signal wiring connections to the communications are made through the communications port removable termin al bock connectors and through RJ- 11 and RJ-45 connectors. All modules have removable term inal blocks for convenie[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-6 Table 5-3. Built-in LOI EIA-232 Signal Routing Signal LOI Function RJ-45 Pins on ROC827 Description DTR Data Terminal Ready 3 Originated by the ROC827 Data Terminal Equipment (DTE) to instruct the Data Communication Equipment (DCE) to setup a conne ction. DTE is running and ready to communi[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-7 Pin Wire Color RJ-45 Pins on ROC800- Series 4 Red 5 5 Green 3 6 Yellow 2 7 Brown 7 8 Gray 8 5.5.1 Using the LOI 1. Plug the LOI cable into the LOI RJ-45 connector of the ROC827. 2. Connect the LOI cable to the D- Sub 9 pin (F) to RJ-45 modular converter. 3. Plug the modular converter into t[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-8 You can link Ethernet networks togeth er to form extended networks using bridges and routers. Table 5-6. Ethernet Signal LEDs Signal Function RX Lit when currently receiving. TX Lit when curre ntly transmitting. COL Lit when Ethernet Packet Collision detecte d. LNK Lit when Ethernet has lin[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-9 greater than 400°C (752°F), use plenum rated cables to ensure that cable attenuation remains w ithin specification. When connecting two twisted-pair Me dium Attachment Units (MAUs) or repeaters together over a segm ent, wire the transm it data pins of one eight- pin connector to the recei[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-10 The EIA-232 (RS-232) communications includes LED indicators that display the status of the Receive (R X), Transm it (TX), Data Terminal Ready (DTR), and Ready To Send (RTS) control lines. Table 5-7 defines the built-in EIA-232 (RS-232) terminals at the Comm 2 port and their function signal[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-11 EIA-422/485 (RS-422/485) commun ication modules include LED indicators that display th e status of receive and transmit activity. Refer to Tables 5-9 and 5-10. Table 5-9. EIA-422 (RS-422) Signal Routing – Comm3, Comm4, and Comm5 Signal RS-422 Function Terminal A RX + Lit when module (Com[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-12 Figure 5-5. EIA-422/485 (R S-422/485) J4 Jumper Table 5-11. EIA-422 (RS-422) Module Terminated Not Terminated Jumper TER Out Half Full TER Out Half Full J3 x x J4 x x J5 x x J6 x x Table 5-12. EIA-485 (RS-485) Module Terminated Not Terminated Jumper TER OUT Half Full TER OUT Half Full J3 x[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-13 Note : When installing a dial-up modem module, you must remove power from the ROC827. The dial-up modem provides communi cations with speeds up to 14.4K bps with V.42 bis and V.42, MNP2-4 and MNP10 error correction, and is FCC Part 68 approved for use with PSTNs. The FCC label on the modul[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-14 5.10 Multi-Variable Sensor (MVS) Interface Modules The Multi-Variable Sensor (MVS) pr ovides differential pressure, static pressure, and temperature inputs to the ROC827 unit for orifice flow calculation. The MVS module consists of interface electronics that provide the communications link[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-15 Figure 5-6. MVS Jumper J4 (Shown Not Terminated) Four wires run from the MVS module terminal block and connect to the sensor. The wires should be a mini mum size of 22 AWG and a maximum length of 1220 m (4000 ft). Note : Insulated, shielded, twisted-pair wiring is required when using MVS s[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-16  MVS modules are isolated on the fi eld side. Be aware that you can induce ground loops by ty ing commons together. 5.11 HART Interface Module The HART ® Interface module allows a ROC827 to communicate with HART devices using the Highway A ddressable Remote Transducer (HART) protocol. [...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-17 second per poll for each device, so with five devi ces per channel the maximum poll time for the channel would be five seconds. Note : The ROC827 does not support HART devices configured in Burst mode (in which the device sends info rmation without a prior request). If you have a HART devi[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-18 Figure 5-7. HART Interfa ce Module Field Wiring Figure 5-8. HART Channels 1 and 3 (back side of board) CH1 I/O Switch CH3 I/O Switch Representative Internal Circuit Field Wiring[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-19 Figure 5-9. HART Channels 2 and 4 (front side of board) CH4 I/O Switch CH2 I/O Switch[...]

ROC827 Instruction Manual Issued Mar-06 Communications 5-20 5.12 Related Specification Sheets Refer to the following specifi cation sheets (available at www.EmersonProcess.com/flow ) for additional and most-current information on each of the communications m odules. Table 5-17. Related Documentation Name Form Number Part Number Communications Mo du[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-1 Chapter 6 – T roubleshooting This chapter provides generalized guidelines for troubleshooting the ROC827. Perform the procedures in this chapter before you remove power from the ROC827 for any reas on, after you restore power to the ROC827, and if you disassemble the ROC827. Use the foll[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-2 6.2 Checklists If the LEDs do not display:  By default, LEDs on the communication modules and I/O modules enter Sleep mode after five minutes.  To turn the LEDs on, press the LED button located on the CPU for one second. Note : Using the ROCKLINK 800 software, you can disable this fe[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-3 6.2.3 Software If you are experiencing problems with the ROC827 that appear to be software-related, try resetting the ROC827. Note : During a reset and subsequent re-start, the ROC827 loses configuration and log data. Before you attempt any type of reset, back up your configuration and log[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-4  Reset the MVS module back to f actory defaults. Refer to the ROCLINK 800 Configuration Software User Manual (Form A6121). Note : If you believe an MVS module is damaged or faulty, contact your sales representative for repair or replacem ent. 6.3 Procedures Use the following procedures [...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-5 Caution Ensure all input devices, output dev i ces, and processe s remain in a safe state upon restoring power. An uns afe s tate could result in property damage. When working on units located in a hazardous ar ea ( where explosive gases may be present), make sure the area is in a non-h az[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-6 Caution Failure to exercise proper electrosta tic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted o peratio ns. 1. Connect a multimeter across the sca ling resistor connected to the + and COM te[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-7 9. Remove the test equipment. 6.3.4 Troubleshooting Analog Output Modules Equipment Required :  Multimeter.  PC running ROCLINK 800 software. Caution Failure to exercise proper electrosta tic discharge precautions, such as wearing a grounded wrist strap may reset the processor or dam[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-8 2. Connect to ROCLINK 800 software. 3. Select Configuration > I/O > DI Points . 4. Select the correct Discre te Input Point Number. 5. Place a jumper across a channel in put term inal (1-8) and COM. 6. The Status should change to On. With no jumper on the channel terminal and COM, th[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-9 3. Measure the resistance across terminals + and – . A reading of 0 (zero) ohms should be obtained. No c ontinuity should be indicated. 4. Measure the resistance across the terminals + and –. The reading should indicate an open circuit. 6.3.8 Troubleshooting Pulse Input Modules Equipme[...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-10 Caution Failure to exercise proper electrosta tic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted o peratio ns. 1. Disconnect the field wiring at the RTD module terminations. 2. Connect to the [...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-11 Do not try to verify a thermocouple th at is connected and actively being monitored by a ROC827 by measur ing the voltage at the ROC827 terminal blocks. It is suggested that you independently verify the process temperature, by using a certified thermometer in an adjacen t thermowell, and [...]

ROC827 Instruction Manual Issued Mar-06 Troubleshooting 6-12 4. Verify the thermocouples have th e correct construction (ungrounded) and are not grounded by other means. 5. Verify you are using the correct th ermocouple wire all the way from the thermocouple to the ROC827 with minimal connections. 6. Verify the wiring run is adequa tely protected f[...]

ROC827 Instruction Manual Issued Mar-06 Calibration 7-1 Chapter 7 – Calibration This section provides information a bout calibration procedures for the Analog Input (AI) modules, HART Input module, RTD Input module, and Multi-Variable Sensor (MVS) In put m odule. For the full calibration procedure, refer to the ROCLINK 800 Configuration Software [...]

ROC827 Instruction Manual Issued Mar-06 Calibration 7-2[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-1 Appendix A – Glossary Note: This is a generalized glossary of terms. Not all the term s may necessarily correspond to the particular device or software described in this manual. For that reason, the te rm “ROC” is used to identify all varieties of Remote Operations Controllers (including RO[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-2 C (continued) Comm Module Module that plugs into a ROC to provide a channel for communications via a specified communications proto col, su ch a s EIA-422 (RS-422) or HART. CF Compare Flag; stores the Signal Value Discrete (SV D). Configuration Refers either to the process of setting up the softw[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-3 D (continued) DVM Digital voltmeter. DVS Dual-Variable Sensor. A device that provides st atic and differential pre ssure inpu ts to a ROC. E EDS Electronic Static Discharge. EEPROM Electrically Erasable Programmable Read-O n ly Memory, a form of permanent memory on a ROC. EFM Electronic Flow Mete[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-4 H HART Highway Addressable Remote Transducer. Holding Register Analog output number value to be read. Hw Differential pressure. Hz Hertz. I, J IC Integrated Circuit. Also, Industry Canada (more recent ly known as Measurement Canada), an organization that grant s cu stody transfer approvals on cer[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-5 M m Meter. mA Milliamp(s); one thousandth of an ampere. MAC Address Media Access Control Add ress; a hardware address that uniquely identifies each node of a network. Manual mode For a ROC, indicates that the I/O scanning has been disabled. MAU Medium Attachment Unit. MCU Master Controller Unit. [...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-6 P, Q (continued) P/DP Pressure/Differential Pressure. PI Pulse Input. PID Proportional, Integral, and Derivative control feedb ack actio n. PIT Periodic Timer Interrupt. PLC Programma bl e Logic Controller. Point Software-orie nted term for an I/O channel or some other function, such as a flow ca[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-7 R (continued) RS-232 Serial Communications Protocol u sin g three o r more signal lines, intended for short distances. Also referred to as the EIA-2 32 stan dard. RS-422 Serial Communications Protocol u sin g four signal lin es. Also referred to as the EIA-422 standard. RS-485 Serial Communicatio[...]

ROC827 Instruction Manual Issued Mar-06 Glossary A-8[...]

ROC827 Instruction Manual Issued Mar-06 Index I-1 Index + +12 V dc Analog I nput .................................................... 4-6 Pulse I nput .................................................... 4-13 +24 V dc Analog I nput .................................................... 4-6 Pulse I nput ................................................[...]

ROC827 Instruction Manual Issued Mar-06 Index I-2 Discrete Output Relay LEDs .............................................................. 4-11 Troubleshooting ............................................... 6-8 Discrete Ou tputs ................................................ 4-10 LEDs ............................................................[...]

ROC827 Instruction Manual Issued Mar-06 Index I-3 Fuse Installin g .......................................................... 3-5 Removing ........................................................ 3-5 G Gauges, wire ................................................. 4-6, 5-5 Ground ................................................................. 2-4[...]

ROC827 Instruction Manual Issued Mar-06 Index I-4 Low Mode s .................................................... 1-13 Operatin g ....................................................... 1-13 Requirement s .................................................. 3-8 Sleep Mode ................................................... 1-14 Standby Mode .........[...]

ROC827 Instruction Manual Issued Mar-06 Index I-5 5- 7. Built-in EIA-232 (RS-232) Signal Routing – Comm2 ........................................................ 5-10 5- 8. EIA-232 (RS-232) Communi cation Module Signal Routing – Comm3, Comm4, and Comm5 .................................................................... 5-10 5- 9. EIA-422 (RS-4[...]

ROC827 Instruction Manual Issued Mar-06 Index I-6 If you have comments or questions regarding thi s manual, please direct them to your local sale s representative or contact: Emerson Process Management Flow Computer Division Marshalltown, IA 50158 U.S.A. Houston, TX 77065 U.S.A. Pickering, North Yorkshire UK Y018 7 JA Website: www.EmersonProcess.co[...]