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ABB AC 800PEC Aluminium applications

Aluminium applications

– AC 800PEC unit controller ↔ AC 800PEC master controller communicates via PEC – PEC fibre optic link

(100 μs)

– Can be independent of the main controller control unit

– Allows emergency operation (full smooth current control in emergency mode without AC 800PEC,

only in combination with DCS800 pre-magnetisation)

– Predictive maintenance functions can be included

– Open circuit, overcurrent, undervoltage and overvoltage protection packages included in software

– Newly developed OPC (Open Circuit Protection) stand-alone PLC (Programmable Logic Controller)

that can be used in conjunction with AC 800PEC main controller functions or

as a stand-alone protection during main board maintenance

– Controlled shutdown in the event of an event without immediate tripping → reduced disruption to the

production process

– Potline load fluctuation detection and load shedding integrated into the application software

– Load tap converter fast tap function to prevent DC current overloads during disturbances

– Special Potline-to-Earth Resistance Measurement System (PERMS) based on the AC 800PEC series

– Maximum power regulation

– Prevents excessive power consumption and supports your generator

– Maximum DC voltage regulation to stabilise the process

GE IC693CMM321 Ethernet Interface Module Board Indicators

Four LEDs are located at the top of the board.  The Restart pushbutton is located immediately

below the LEDs.  The RS-232 serial port with the RJ-11 connector is the Station Manager port.

The RS-485 serial port with the 15-pin D connector located below the Station Manager port is the

module’s Downloader port.  The 14-pin AAUI connector, facing downward, is the Transceiver

port.  The Default MAC Address label is attached to the outside of the plastic housing.

Board Indicators

There are four LEDs on the Ethernet Interface:  OK, LAN, SER, and STAT.  These LEDs can be

ON, OFF, BLINKING slow, or BLINKING fast.  They indicate the state the Interface is in, traffic

on the Transceiver port and Downloader port, and when an exception event has occurred.

Restart Button

The Restart button serves four functions:  LED test, Restart, Restart and Reload, and Restart and

Enter Maintenance Utility.  The Restart button is inaccessible when the front cover of the Ethernet

Interface is closed.

Serial Ports

There are two serial ports on the Ethernet Interface:  the Station Manager Port and the Downloader Port.

The Station Manager Port.  This RS-232 port is used to connect a terminal or terminal emulator

to access the Station Manager software on the Ethernet Interface.  This port uses a  6-pin, RJ-11

connector.  The IC693CBL316 Station Manager cable is ideal for connecting to this port .

The Firmware Upgrade Port.  The 15-pin, D-type, RS-485 port is used to connect to the PC

Downloader in case the communications software in the Ethernet Interface needs to be updated.

Use the IC690ACC901 miniconverter/cable kit for this connection.

ABB has designed its maintenance schedule

Preventive maintenance program

ABB has designed its maintenance schedule for all contactor

families, based on its technical knowledge of the products and

on its experience in the field.

The preventive maintenance program has the following main targets:

• Check the preservation and the efficiency status of the apparatus

• Anticipate the trend of deterioration of the contactors, signalling

the need for replacement of excessively worn out components,

where available, or suggest alternative solutions for bringing them up to date

• Increase the life cycle of the installation, proposing proactive

maintenance and replacing obsolete components.

Provided services

Considering the importance of the maintenance activity and

the required technical know-how, ABB guarantees professional

competence. Interventions are performed by ABB recommended

skilled technicians. After the inspection activities, ABB technicians

give all the indications related to the future maintenance needs and

any possible corrective actions, while releasing the final report.

ABB Preventive maintenance for AF1350 … AF2650 contactors Benefits

Benefits

Preventive Maintenance creates value over the long-term by

• Providing the best management of maintenance costs, in

particular:– Less expensive direct costs of maintenance, by reducing

the charges due to urgent situations–  Less expensive indirect costs of the installation shut-down,

taking advantage of scheduled stops.

• Ensuring better efficiency and reliability of the equipment

• Extending the contactor’s life

• Guaranteeing the safety of the installation for longer time.

Provided services

Considering the importance of the maintenance activity and

the required technical know-how, ABB guarantees professional

competence. Interventions are performed by ABB recommended

skilled technicians. After the inspection activities, ABB technicians

give all the indications related to the future maintenance needs and

any possible corrective actions, while releasing the final report.

ABB DC switching contactors Features and benefits

Features and benefits

Powerful

•  1000 V DC switching ratings (IEC).

•  UL (508) rated up to 600 V DC.

Flexible

•  Wide control voltage range (e.g. 100-250 V AC/DC) means

less versions covering the entire range.

•  PLC interface with 24 V DC / 10 mA for GAF/AF400…2050.

•  Ideal for remote and fast operation.

Efficient

•  The AF electronic coil interface reduces power consumption

5-10 times at holding compared to conventional contactors.

Reliable

•  The GAF contactor is based on the well proven AF contactor.

•  Less sensitive to voltage drops due to a drop-out voltage

of 55% of the lower nominal value along with 20 ms sag

and dip immunity. These features avoid the problems with

contactor chattering and welding.

•  Elimination of contact bounce and chattering allows for

increased reliability and service life.

Quiet

•  DC powered coil makes the contactor virtually noise free.

Easy

•  The external dimensions of the GAF contactors are the same

as corresponding AF contactors making it easy to order and install.

•  Existing add on accessories for A/AF range of three pole

contactors will fit the GAF contactors.

Kongsberg RMP420-Remote Multipurpose Input/Output

RMP420-Remote Multipurpose Input/Output

RPM420 is a multipurpose I/O module for use in Alarm monitoring and

Integrated Control Systems.  RMP420 is designed for 32 field input channels

in single topologies. Its interface towards the host control computer (RCU) is

provided by redundant I/O bus.

The module is approved for Ex Zone 2 applications.

Functions

• 32 software configurable multipurpose solid-state channels.

• Analog and Digital Input and Output (AI, AO, DI and DO).

• 2 or 3 wire Resistance Temperature Detector (RTD).

• 2 channels can be configured as pulse/frequency/encoder input.

• Short-circuit protected I/O loop power output.

• Dual Remote I/O process BUS interface for redundant communication with host computer(s).

• Communication ports galvanically insulated from other module circuitry.

• Loop monitoring (per channel).

BENEFITS

• Over-voltage protection

• Extensive module diagnos tics

• I/O channels online configurable

• Soft and hard fail-safe

• Dual watchdog

• Certified for use in hazardous area zone 2

• RIO module and I/O loop, powered from the same source

• Automatic recovery protection e.g. automatic start of faulty channels

• Easy installation and replacement

• Simple and safe FW up grade

• Status LED

Woodward 505DR Control specifications

Control specifications

Inputs

– Power Supply Low voltage models 18-32 VDC High voltage models 88-264 VAC and 90-150 VDC

– Speed: 2 passive MPUS or active proximity probes (0.5 – 32000 Hz)

– Discrete Inputs 19 configurable contact inputs (16 additional contact inputs can be added using LinkNet

HT)

– Analogue Inputs 8 configurable 4-20 mA (16 inputs or 8 RTD inputs can be added using LinkNet HT)

Outputs

– Valve/actuator driver: 2 actuator outputs, 4-20 mA or 20-200 mA

– Discrete Outputs:

– 7 configurable relay outputs (16 discrete outputs can be added using the LinkNet HT module)

– Analogue Outputs 6 programmable 4-20 mA outputs (4 inputs can be added using the LinkNet HT

module)

Communications

– Ethernet 3 ports (Modbus TCP or OPC)

– Serial 1 port (ASCII or RTU, RS-232 or RS-485)

– CAN: 4 ports, supports LinkNet HT, VariStroke, and power management devices

Operating Conditions

– Ambient air temperature: -25 to +65C

– Humidity Lloyd’s ENV2 Test #1

– Dry heat Lloyd’s ENV3

– Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

– Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

– Vibration Lloyd’s ENV2 Test #1

– Resistance to particulate contamination IEC 60664-1 Class 2

– IEC 60068-2-60 part 2.60 methods 1 and 4

– Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

– Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)

Woodward 505DR Control specifications

Control specifications

Inputs

– Power Supply Low voltage models 18-32 VDC High voltage models 88-264 VAC and 90-150 VDC

– Speed: 2 passive MPUS or active proximity probes (0.5 – 32000 Hz)

– Discrete Inputs 19 configurable contact inputs (16 additional contact inputs can be added using LinkNet

HT)

– Analogue Inputs 8 configurable 4-20 mA (16 inputs or 8 RTD inputs can be added using LinkNet HT)

Outputs

– Valve/actuator driver: 2 actuator outputs, 4-20 mA or 20-200 mA

– Discrete Outputs:

– 7 configurable relay outputs (16 discrete outputs can be added using the LinkNet HT module)

– Analogue Outputs 6 programmable 4-20 mA outputs (4 inputs can be added using the LinkNet HT

module)

Communications

– Ethernet 3 ports (Modbus TCP or OPC)

– Serial 1 port (ASCII or RTU, RS-232 or RS-485)

– CAN: 4 ports, supports LinkNet HT, VariStroke, and power management devices

Operating Conditions

– Ambient air temperature: -25 to +65C

– Humidity Lloyd’s ENV2 Test #1

– Dry heat Lloyd’s ENV3

– Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

– Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

– Vibration Lloyd’s ENV2 Test #1

– Resistance to particulate contamination IEC 60664-1 Class 2

– IEC 60068-2-60 part 2.60 methods 1 and 4

– Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

– Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)

Woodward The 505DR can communicate directly with the plant DCS

Communication

The 505DR can communicate directly with the plant DCS and/or operator control panel using Modbus

TCP or OPC communications.

Serial communication is also supported using RS-232 or RS-485 and ASCII or RTU Modbus.

Control PIDs can perform process control or be used as limiters for speed/load dynamics,

pumping/discharge pressures, cascade, auxiliary, intake plenum, exhaust plenum, and rotor acceleration.

System Protection

– Integrated overspeed protection logic and test functions

– First open indication on 15 shutdown inputs

– External alarm indication on 15 inputs

– Stuck at critical speed band logic

– Bufferless transfer between control modes and during Syscon switchover

– Operation and configuration password security

Operating Conditions

– Ambient air temperature: -25 to +65C

– Humidity Lloyd’s ENV2 Test #1

– Dry heat Lloyd’s ENV3

– Salt Spray: US MIL-STD-810. Method 509.2 proc. 1

– Shock: US MIL-STD-810C, Method 516.2-1 proc. 1B

– Vibration Lloyd’s ENV2 Test #1

– Resistance to particulate contamination IEC 60664-1 Class 2

– IEC 60068-2-60 part 2.60 methods 1 and 4

– Resistance to gaseous contamination: coating is resistant to NO2. CO2. SO2 and H2S.

– Battelle Laboratories Class III (IEC 60721-3-3 Categories 3C1 and 3C2)

Woodward The 505DR is a G-efficient redundant turbine controller

Cost-effective design

The 505DR is a G-efficient redundant turbine controller.

It consists of a turbine controller, system sequencer, operator control panel and first-out indicator.

The design minimises external equipment and wiring for easy troubleshooting.

Like the 505XT, the 505DR can be fully configured in the field

(under password control by knowledgeable personnel) and minor functional

changes can be made while the turbine is running online.

Minor functional changes can be made online while the turbine is running.

Like the MicroNet Plus, the 505XT system designates one controller

as the System Controller (Syscon), actively controlling the fan.

The second device is configured as a backup.

The system automatically evaluates the health of the Syscon and initiates a fast switchover in the event of

a failure.

Switchover can also be initiated manually. The system closely synchronises

the Syscon’s software status and memory with the backup,

ensuring that the control output remains stable and does not affect turbine operation (a true ‘bufferless’

switchover).

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