Symphony BRC-100 User manual

Instruction
Harmony Series
Bridge Controller and Processor Bus Adapter
BRC-100 and PBA-100

WBPEEUI230017B1
Preface
The BRC-100 Harmony Bridge Controller is a high-perfor-
mance, high-capacity process controller. It is a rack controller
designed to interface with both Harmony I/O blocks and Har-
mony rack I/O in the Symphony Enterprise Management and
Control System. The Harmony bridge controller is fully com-
patible with the INFI 90®OPEN system in functionality, com-
munication and packaging. The Harmony bridge controller
collects process I/O, performs control algorithms and outputs
control signals to process level devices. It also imports and
exports process data of other controllers and system nodes,
and accepts control commands from operators and computers
connected to the network.
This instruction provides information about how the Harmony
bridge controller works, and how to install, configure, operate
and troubleshoot the module.
The Harmony bridge controller is designed for redundancy.
This can be achieved while remaining connected to the Hnet, or
without, using an optional BRC redundancy kit.

WBPEEUI230017B1
List of Effective Pages
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed fig-
ures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
Total number of pages in this instruction is 99, consisting of the following:
Page No. Change Date
Preface 04 December 2000
List of Effective Pages 04 December 2000
iii through x 04 December 2000
1-1 through 1-8 04 December 2000
2-1 through 2-8 04 December 2000
3-1 through 3-19 04 December 2000
4-1 through 4-5 04 December 2000
5-1 through 5-23 04 December 2000
6-1 through 6-4 04 December 2000
7-1 through 7-3 Original
8-1 04 December 2000
A-1 through A-8 Original
B-1 through B-7 04 December 2000
Index-1 through Index-3 04 December 2000
When an update is received, insert the latest changed pages and dispose of the superseded
pages.

WBPEEUI230017B1 iii
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Overview .................................................................................................................. 1-1
Intended User .......................................................................................................... 1-2
Hardware Description .............................................................................................. 1-2
Faceplate ............................................................................................................. 1-3
Circuit Board ....................................................................................................... 1-3
Hardware Application............................................................................................... 1-3
Features .................................................................................................................. 1-3
Instruction Content.................................................................................................. 1-4
How to Use this Instruction ...................................................................................... 1-4
Glossary of Terms and Abbreviations........................................................................ 1-5
Reference Documents............................................................................................... 1-6
Related Nomenclatures ............................................................................................ 1-6
Specifications........................................................................................................... 1-6
Section 2 Description and Operation .........................................................................2-1
Introduction............................................................................................................. 2-1
Operation................................................................................................................. 2-1
Circuitry .................................................................................................................. 2-2
Microprocessor..................................................................................................... 2-2
Clock and Real-Time Clock ................................................................................... 2-2
Memory................................................................................................................ 2-2
Direct Memory Access .......................................................................................... 2-3
Controlway........................................................................................................... 2-4
Redundancy Link ................................................................................................. 2-4
Hnet Communication ........................................................................................... 2-5
I/O Expander Bus ................................................................................................ 2-5
I/O Section .......................................................................................................... 2-6
Serial Channels.................................................................................................... 2-6
Station Link ......................................................................................................... 2-6
Power................................................................................................................... 2-7
Section 3 Installation ....................................................................................................3-1
Introduction............................................................................................................. 3-1
Special Handling ...................................................................................................... 3-2
Unpacking and Inspection........................................................................................ 3-2
Dipswitches and Jumpers ........................................................................................ 3-3
Dipswitch SW5 - Module Address ......................................................................... 3-4
Dipswitch SW2 - Normal Operating Options.......................................................... 3-5
Dipswitch SW2 - Special Operations ..................................................................... 3-5
Dipswitch SW3 - Module Options ......................................................................... 3-8

iv WBPEEUI230017B1
Table of Contents (continued)
Section 3 Installation (continued) ..........................................................................................
Dipswitch SW4 - Module Options ..........................................................................3-8
Jumpers ...............................................................................................................3-8
Module Mounting Unit Preparation ...........................................................................3-9
Module Slot Assignments ......................................................................................3-9
Dipshunts ..........................................................................................................3-10
Controlway Cable................................................................................................3-10
PBA Board Installation........................................................................................3-11
Mounting Bracket ...........................................................................................3-11
Cable and Terminator .....................................................................................3-12
Mounting ........................................................................................................3-13
BRC Redundancy Kit Installation ........................................................................3-16
Module Installation.................................................................................................3-18
Pre-Installation Check ........................................................................................3-18
Installation .........................................................................................................3-19
Section 4 Operating Procedures .................................................................................4-1
Introduction .............................................................................................................4-1
Startup.....................................................................................................................4-1
Module LEDs............................................................................................................4-2
Front Panel LEDs..................................................................................................4-2
Red/Green Status LED .........................................................................................4-3
Stop/Reset Switch ....................................................................................................4-3
Modes of Operation...................................................................................................4-4
Section 5 Troubleshooting ..........................................................................................5-1
Introduction .............................................................................................................5-1
Error Codes ..............................................................................................................5-1
Flowcharts ...............................................................................................................5-5
Diagnostics ..............................................................................................................5-5
Overview...............................................................................................................5-5
Diagnostic Test Selection ......................................................................................5-8
LED Display .......................................................................................................5-11
Module Status Summary ........................................................................................5-12
Card Edge Connectors ............................................................................................5-17
Section 6 Maintenance .................................................................................................6-1
Introduction .............................................................................................................6-1
Preventive Maintenance Schedule .............................................................................6-1
Equipment and Tools Required .................................................................................6-1
Preventive Maintenance Procedures ..........................................................................6-2

WBPEEUI230017B1 v
Table of Contents (continued)
Section 6 Maintenance (continued) .......................................................................................
Printed Circuit Board Cleaning ............................................................................. 6-2
General Cleaning and Washing ......................................................................... 6-3
Edge Connector Cleaning.................................................................................. 6-3
Checking Connections.......................................................................................... 6-4
Section 7 Repair and Replacement .............................................................................7-1
Introduction............................................................................................................. 7-1
Module Replacement ................................................................................................ 7-1
PBA Board Replacement........................................................................................... 7-2
Section 8 Replacement and Spare Parts ....................................................................8-1
Parts........................................................................................................................ 8-1
Appendix A Online Configuration .............................................................................. A-1
Introduction............................................................................................................. A-1
Setup....................................................................................................................... A-1
Operation................................................................................................................. A-2
Backup Cycle ....................................................................................................... A-3
Primary Cycle....................................................................................................... A-6
Appendix B NTMP01 Termination Unit ...................................................................... B-1
Description ..............................................................................................................B-1
List of Figures
No. Title Page
1-1. Harmony Bridge Controller Architecture.................................................... 1-2
2-1. Functional Block Diagram......................................................................... 2-3
3-1. BRC Module Layout ................................................................................. 3-3
3-2. Controlway Cable Installation ................................................................. 3-11
3-3. PBA Installation ...................................................................................... 3-14
3-4. PBA Connector Identification................................................................... 3-15
3-5. BRC Redundancy Kit Installation ............................................................ 3-17
3-6. Hood Connector Assembly Connector Identification ................................. 3-18
4-1. Front Panel ............................................................................................... 4-2

vi WBPEEUI230017B1
List of Figures (continued)
No. Title Page
5-1. Troubleshooting Flowchart (Serial Port) .....................................................5-6
5-2. Troubleshooting Flowchart (Status LED)....................................................5-7
5-3. LEDs - Pass/Fail .....................................................................................5-12
A-1. Backup Cycle ........................................................................................... A-6
A-2. Primary Cycle ........................................................................................... A-8
B-1. DTE Jumper Configuration (NTMP01) ....................................................... B-2
B-2. DCE Jumper Configuration (NTMP01)....................................................... B-2
B-3. Nonhandshake Jumper Configuration (NTMP01)....................................... B-3
B-4. Loopback Jumper Configuration (NTMP01) ............................................... B-3
B-5. Jumpers J3 through J10 Configuration (NTMP01) .................................... B-4
B-6. NTMP01 Board Layout.............................................................................. B-5
B-7. NTMP01 Cable Connections (Redundant BRC Modules/PBA Boards) ........ B-6
B-8. Cable Connections (Redundant BRC Modules Using BRC Redundancy Kit) B-7
List of Tables
No. Title Page
1-1. Glossary of Terms and Abbreviations .........................................................1-5
1-2. Reference Documents ................................................................................1-6
1-3. Related Nomenclatures ..............................................................................1-6
1-4. Specifications ............................................................................................1-7
3-1. Dipswitch SW5 Settings (Operation)...........................................................3-4
3-2. Dipswitch SW5 Settings (Address)..............................................................3-5
3-3. Dipswitch SW2 Settings (Operating Options)..............................................3-6
3-4. Dipswitch SW2 Settings (Special Operations) .............................................3-7
3-5. Dipswitch SW4 Settings (Module Options)..................................................3-8
3-6. Jumpers Settings (J1 through J4) ..............................................................3-9
5-1. Error Codes ...............................................................................................5-1
5-2. Status LED and Other Conditions..............................................................5-4
5-3. DSO and BRC Setup for I/O Expander Bus Test ........................................5-8
5-4. Diagnostic Dipswitch Settings....................................................................5-8
5-5. Diagnostic Tests ........................................................................................5-9
5-6. Status Report ..........................................................................................5-13
5-7. Status Report Field Descriptions..............................................................5-13
5-8. P1 Pin Assignments (BRC) .......................................................................5-17
5-9. P2 Pin Assignments (BRC) .......................................................................5-18
5-10. P3 Pin Assignments (BRC)1,2 ..................................................................5-18
5-11. P4 Pin Assignments (BRC) .......................................................................5-19
5-12. P1 Pin Assignments (PBA) ........................................................................5-19

WBPEEUI230017B1 vii
List of Tables (continued)
No. Title Page
5-13. P3 Pin Assignments (PBA) ....................................................................... 5-20
5-14. P4 Pin Assignments (PBA) ....................................................................... 5-20
5-15. P5 Pin Assignments (PBA) ....................................................................... 5-21
5-16. P5 Pin Assignments (Hood Connection Assembly) .................................... 5-22
6-1. Preventive Maintenance Schedule.............................................................. 6-2
8-1. Miscellaneous Nomenclatures ................................................................... 8-1
8-2. Cable Nomenclatures ................................................................................ 8-1
8-3. Miscellaneous Parts .................................................................................. 8-1
A-1. Legend of Symbols .................................................................................... A-3
A-2. Backup Cycle ............................................................................................ A-3
A-3. Primary Cycle............................................................................................ A-7

viii WBPEEUI230017B1
Safety Summary
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
Special Handling
This module uses electrostatic sensitive devices.
SPECIFIC
WARNINGS
Disconnect power before installing dipshunts on the module mount-
ing unit backplane. Failure to do so will result in contact with cabinet
areas that could cause severe or fatal shock. (p. 3-9)
Disconnect power before installing the processor bus adapter
mounting bracket on the module mounting unit backplane. Failure to
do so will result in contact with cabinet areas that could cause
severe or fatal shock. (p. 3-11)
Wear eye protection whenever working with cleaning solvents.
When removing solvents from printed circuit boards using com-
pressed air, injury to the eyes could result from splashing solvent as
it is removed from the printed circuit board. (p. 6-1)
SPECIFIC
CAUTIONS
Never operate the BRC module with the machine fault timer circuit
disabled (jumper pins connected). Unpredictable module outputs
and configuration corruption may result. The unpredictable module
outputs may damage control equipment connected to the BRC
module.
To avoid potential module damage, evaluate your system for com-
patibility prior to module installation. This module uses connections
to the module mounting unit backplane that served other functions
in early Network 90 systems. (p. 3-16)

WBPEEUI230017B1 ix
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also pro-
vide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available though the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and schedul-
ing.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.