Bailey 40 Series Hardware Manual Download

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Process Control and
Automation Solutions
from Elsag Bailey Group

E96-192-5

Operator Interface Console (40 Series)

Hardware Manual

(IIOIC42)

Summary of Contents for 40 Series

Page 1: ...Process Control and Automation Solutions from Elsag Bailey Group E96 192 5 Operator Interface Console 40 Series Hardware Manual IIOIC42...

Page 2: ...UIPEMENTS LECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR FR QUENCE RADIO DES PR CAUTIONS DEVRONT TRE PRISES LORS DE L UTILISATION DU MAT RIEL DE COMMUNICATION PORTATIF LA PRUDENCE EXIGE QUE LES PR...

Page 3: ...nal instructions that explain how to set up and use the OIC console and OIS station The instructions include File Utilities Provides software load upgrade and maintenance procedures as well as save an...

Page 4: ...6 Original 6 1 through 6 30 Original 7 1 through 7 2 Original A 1 through A 4 Original Index 1 through Index 3 Original When an update is received insert the latest changed pages and dispose of the s...

Page 5: ...hen the mounting bolts are removed The monitor weighs approximately 27 kilograms 60 pounds and can cause bodily injury if it is allowed to slide out by itself Support the monitor before removing the r...

Page 6: ...s qui ris quent d atteindre les yeux p 5 3 Supportez le moniteur avant de retirer les deux boulons d ancrange l arri r Lorsque ces boulons d ancrage sont retir s l e moniteur glissera et sorta l arri...

Page 7: ...circuit de raccordement de l interface du clavier r gler les interrupteurs 5 6 et 7 de SW1 la position ferm e ON R gler les interrupteurs 1 4 et 8 de SW1 la position ouverte OFF Si les interrupteurs d...

Page 8: ...LETS 3 5 OIC INSTALLATION 3 5 IIOIC421 Tabletop Installation and Setup 3 6 IOIC421 Tabletop Wiring Connections and Cabling 3 6 IIOIC422 Console Setup and Installation 3 9 IIOIC422 Console Wiring Conne...

Page 9: ...COMPONENT DESCRIPTION AND REPLACEMENT 6 1 INTRODUCTION 6 1 IIMKM02A MULTIBUS KEYBOARD MODULE 6 1 IIMKM02A MULTIBUS KEYBOARD MODULE REPLACEMENT 6 3 MULTIBUS CARD CAGE 6 4 FAN ASSEMBLY FOR THE CARD CAGE...

Page 10: ...K REFERENCE INFORMATION A 1 INTRODUCTION A 1 List of Tables No Title Page 1 1 IIOIC42 Models 1 4 1 2 Glossary of Terms and Abbreviations 1 6 1 3 Reference Documents 1 6 1 4 Hardware Nomenclature 1 7 1...

Page 11: ...P02 Annunciator Display Panel 3 26 3 21 NADS03 Annunciator Display Panel SW1 Settings 3 27 3 22 Touch Screen Controller Card Connections 3 29 3 23 Touch Screen Switch and Jumper Settings 3 30 6 1 IIMK...

Page 12: ...of Figures continued No Title Page A 3 IIOIC421 Keyboard Interface Assembly A 2 A 4 Color Monitor A 3 A 5 Touch Screen Controller Board A 3 A 6 IIADP01 IIADP02 and NADS03 A 4 A 7 IIADP01 Multiple Ann...

Page 13: ...ng the system Do not put the console into operation until you read and thoroughly understand this instruction This instruction is a reference for installers with installation and maintenance experienc...

Page 14: ...SSEMBLY MONITOR ASSEMBLY KEYBOARD ASSEMBLY POWER SUPPLY AND MKM BOARD LOCATED INSIDE CASE WORK SURFACE ASSEMBLY REAR VIEW FRONT VIEW POWER SUPPLY TP80560A MULTIBUS CARD CAGE POWER ENTRY PANEL MKM MODU...

Page 15: ...ATOR DISPLAY CPU MOUNTED BEHIND IN VERTICAL POSITION OPERATOR KEYBOARD ASSEMBLY MONITOR ASSEMBLY JOYSTICK QWERTY KEYBOARD POWER ENTRY PANEL POWER SUPPLY AND KEYBOARD INTERFACE ASSEMBLY MOUSE TRACKBALL...

Page 16: ...of the cabinet The alarm relays are for alarm annunciation only IIOIC4221 and IIOIC4222 Console The hardware of the OIC422 console is very similar to the OIS console There are several differences The...

Page 17: ...nts an overview of the OIC consoles and related hard ware It also provides a complete list of specifications Description and Operation Describes the theory of operation of the OIC consoles and related...

Page 18: ...Definition ADP Annunciator display panel CPU Tektronix Model XP400 Logic Module INFI NET Advanced data communication highway MKM The designation MKM in this manual refers to the IIMKM02A multibus key...

Page 19: ...4222 Console style operator console with an upper mounted 19 inch monitor with tilt swivel base and keyboard IIOIC423 Environmental operator console with a 19 inch moni tor and keyboard IIOIC424 Panel...

Page 20: ...ing 20 to 80 noncondensing Recommended minimum 40 Storage 10 to 90 noncondensing 0 3 to 2 4 km 0 2 to 1 5 mi Cooling requirements Heat dissipation Table 1 5 OIC Console Specifications continued Proper...

Page 21: ...on or storage period of less than 60 days SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE Table 1 5 OIC Console Specifications continued Property Characteristic Value Model Height Width Depth cm in cm...

Page 22: ...to INFI NET and Plant Loop com munication highways through the OIS main console It can monitor and allow manual control of a process through color graphics displays which show equipment status and pro...

Page 23: ...model XP400 terminal logic module In the OIC console the CPU sends video signals to the monitor A cable connects the CPU to the RGB connectors on the monitor Figure 2 2 is a block diagram of the IIOI...

Page 24: ...king with static sensitive devices The kit is designed to connect the techni cian and the static dissipating work surface to the same ground point to prevent damage to the static sensitive devices by...

Page 25: ...hipment 4 Use the original packing material or container to store the console 5 Store the console in a place with clean air free of extremes of temperature and humidity Refer to Section 1 for the cons...

Page 26: ...the installation and setup procedure for the OIC model being installed 5 Verify that no power is present to the OIC when making power wiring connections Wire AC power according to the pro cedures in O...

Page 27: ...thermoplastic insulation Wire with a 300 volt or 150 volt rating may be used if it is accepted by local wiring codes Wiring must be protected by cable trays or conduit and suited for the service volt...

Page 28: ...C422 console IIOIC423 environ mental cabinet and IIOIC424 panel mounted auxiliary termi nals Follow all cautions and warnings The OIC console is internally wired when it is shipped Con nect the commun...

Page 29: ...periph eral devices AC power input connects to the power connector on the rear of the keyboard interface assembly Figure 3 2 Figure 3 3 shows cabling requirements The circled numbers illustrate the c...

Page 30: ...19 0 TP35324B 609 6 24 0 MILLIMETERS INCHES DIMENSIONS Bailey WRIST STRAP AC IN AC OUT J2 J3 J1 J5 F1 J4 R G B RESET DEGAUSS 2 NC 1 NC 4 NC 3 NC 6 NC 5 NC 2 CO 1 CO 4 CO 3 CO 6 CO DI 2 DI 1 DO 2 DO 1...

Page 31: ...tor bezel controls Degauss on chassis Brightness on bezel contrast on bezel monitor 8 6639117A1 I O signal P9 on IIMKM02A J1 on chassis inside 9 6639211A1 Power P2 on power supply Cooling fan P2 on ke...

Page 32: ...up to 6 35 millimeters 0 25 inches up down forward or back toward the cabinet to line up the table top Two chrome table alignment pins shipped inside the brass bushings located on each side of each t...

Page 33: ...d installing cableways or conduit Refer to the Site Planning and Preparation instruction for more information Figure 3 4 IIOIC422 Console Dimensions 2 1 TP80547A 2 1 HIGH MONITOR LOW MONITOR MOUNTING...

Page 34: ...BRACKET LEFT BUSHING RIGHT BUSHING ADJUSTABLE MOUNTING BOLTS 3 PER BRACKET PIN ONE PER BUSHING TABLE SUPPORT BRACKET RIGHT BRACKET RIGHT BUSHING TP35437B DIMENSIONS INCHES MILLIMETERS 0 25 6 35 0 25 6...

Page 35: ...0 60 hertz into the termi nal block on the power entry panel Figure 3 9 shows the IIOIC422 cable connections The circled numbers represent the cables Table 3 3 contains the list of those cables and co...

Page 36: ...POWER MAIN POWER ON OFF WARNING AVERTISSEMENT 120 240V TP80548A PERIPHERAL POWER UPPER CRT POW ER SUPPLY LOW ER CRT BLOW ER AUX NOTICE CONNECT PERIPHERAL RIBBON CABLE BEFORE PLUGGING AND POWERING UNIT...

Page 37: ...on backplane Terminal block on DC distribution board 9 6638713A1 Peripheral power P2 on keyboard inter face board P3 on DC distribution board KEYBOARD INTERFACE BOARD CPU M ONITOR M ONITOR BEZEL IIO...

Page 38: ...P3 on IIMKM02A 17 6640368A1 Power P5 on DC distribution board P5 on backplane 18 6640368A1 Power P6 on DC distribution board P6 on backplane 19 6640369A1 DC power P2 on power supply Terminal block on...

Page 39: ...the water Protect the wires and cabling going to the OIC environmental cabinet Run cabling through conduit to the bottom of the cab inet Follow local wiring codes when wiring and installing cableways...

Page 40: ...e meets the rating on the label of TB1 Connect only 120 240 VAC at 50 60 hertz into the terminal block on the power entry panel 2 Connect only 120 240 VAC at 50 60 hertz into the termi nal block on th...

Page 41: ...bezel controls Brightness on power entry panel Contrast on power entry panel Degauss on power entry panel Brightness on bezel Contrast on bezel Monitor 10 6638849A1 NADS03 signal P7 on IIMKM02A P2 on...

Page 42: ...able Name Connect From Connect To KEYBOARD INTERFACE BOARD DC DISTRIBUTION BOARD AIR CONDITIONER OPERATOR KEYBOARD NOT USED OPTIONAL TABLETOP ADP PANEL ENGINEERING KEYBOARD AUX PORT AUX KBD MOUSE TRAC...

Page 43: ...e the procedures when the unit is installed in the panel Torque all fasteners to 39 8 Nm 40 in lbs The back of the power entry panel has a connector for AC input alarm relay outputs 24 VDC and the mon...

Page 44: ...long coiled cord can be stretched to 2 4 meters 8 feet See Figure 3 17 Refer to Table 7 1 for the operator keyboard part number Engineering Keyboard Each IIOIC42 console supports an additional enginee...

Page 45: ...8 on I O distribution board 6 6638719A2 Reset cable P4 on IIMKM02A Reset switch on power entry panel KEYBOARD INTERFACE BOARD POWER SUPPLY LINE FILTER MONITOR MONITOR BEZEL OPERATOR KEYBOARD MOUSE TRA...

Page 46: ...t on chassis and line filter 15 1949448A1 Video RGB Monitor port on OIC CPU RGB on monitor 16 6639031A1 Filter AC IN on monitor Line filter 17 1947950A7 Power AC power AC IN on chassis Figure 3 17 Ope...

Page 47: ...s activated it will continue flashing until the alarm condition is removed Press the pushbutton to call the display or key macro assigned to it Up to four annunciator display panels can be driven from...

Page 48: ...display or key macro assigned to it Up to four annunciator display panels can be driven from an MKM module Maximum cable length is 4 5 meters 15 feet Refer to Figure 3 20 for the dipswitch configurati...

Page 49: ...to an alarm condition the assigned LED turns on Press the pushbutton to call the display or key macro assigned to it Up to four annunciator display panels can be driven from an MKM module Maximum cabl...

Page 50: ...ch screen monitor overlay and sends them to the CPU This accessory requires the addition of a touch screen and a touch screen controller board Table 3 8 lists the parts included with the touch screen...

Page 51: ...Follow all cautions and warnings 2 Follow the directions in the installation kit to attach the touch screen to the face of the monitor Use the Velcro sup plied in the kit 3 Connect the cable to the to...

Page 52: ...ch screen option Figure 3 23 Switch S1 and S2 on the touch screen controller board must also be set 1 Set jumpers J6 and J8 at 2 to 3 on the IIMKM02A board 2 Jumpers J7 and J9 are for future use NOTE...

Page 53: ...instruction manual for details on printer configuration operation and cabling requirements NOTE Port 1 of the CPU will accept either the touch screen option or a printer not both Refer to the manufac...

Page 54: ...aker is off before changing operat ing voltage setting or equipment damage may result Remove power from all peripheral equipment and the console before installing or removing peripheral equipment Equi...

Page 55: ...OOTING The OIC consoles are shipped ready for operation After com pleting the instructions given in Section 3 prepare the unit for service The troubleshooting guide in Table 4 1 helps identify problem...

Page 56: ...er to the console by switching on the line circuit breaker 3 Use a digital voltmeter to measure the AC power at each of the outlets as follows IIOIC421 tabletop keyboard interface assembly has one out...

Page 57: ...ly for the IIOIC421 tabletop 4 Insure that all power supply wiring is correct Refer to Section 3 and Section 6 5 Apply power to the console 6 Measure the DC voltages at the multibus card module backpl...

Page 58: ...as a guideline to assist in establishing good preventive maintenance practices Select the minimum steps required to meet the cleaning needs of your system Personnel performing preventive maintenance...

Page 59: ...per manufacturer s instructions Check power supply output Adjust power supply if needed DC Power Test in Section 5 Check alarm and display LEDs Check the cabinet air filters Clean or replace them as n...

Page 60: ...Check and verify that all other power connections within the cabinet including connections to the power supplies are secure 3 Check and verify that all field wiring connections to the communication mo...

Page 61: ...ning and clean ing edge connectors Use the procedures that meet the needs of each circuit board Remove all dust dirt oil corrosion or any other contaminant from the circuit board Do all cleaning and h...

Page 62: ...2 Minimize electrostatic discharge by using the 80 to 20 isopropyl alcohol to water solution during burnishing 3 Do not use excessive force while burnishing Use only enough force to shine the contact...

Page 63: ...er Entry Panel The system must be shut down to perform this maintenance task 1 Check the tightness of all power wiring screws within the console Torque all screws connected to AC power to 1 58 New ton...

Page 64: ...pending on which type of OIC is being used There are six jumpers on the MKM board to set for proper operation Figure 6 1 Table 6 1 Hardware Nomenclature or Part Number OIC Model Description Hardware D...

Page 65: ...ultibus card cage when the MKM watchdog timer circuit times out Set the jumper to J3 pins one and two for OIC reset on time out Set the jumper to J3 pins two and three for no OIC reset on time out Fac...

Page 66: ...console The multibus keyboard module connects the keyboard interface assembly to the CPU IIOIC422 Console In the IIOIC422 model the MKM board is located in the multi bus card cage Remove the module f...

Page 67: ...for the IIOIC4221 lower moni tor consoles Figure 6 2 shows the front view of the card cage Figure 6 3 shows the rear view of the multibus card cage To remove a multibus card cage 1 Turn off the main c...

Page 68: ...installed points in the direc tion of the air flow 2 Be sure the red striped conductor of the power cord is con nected to the positive terminal of the fan POWER SUPPLY REMOVAL The 130 watt power supp...

Page 69: ...ons Socket Console Connection P1 IIMKM02A IIOIC423 only P2 P3 Keyboard interface board P4 IIADP02 P5 Backplane IIOIC422 only P6 Backplane IIOIC422 only P7 Fans card cage and door IIOIC422 only P8 Fan...

Page 70: ...split cover Do not remove the monitor 3 Mark and disconnect the wires on the power supply 4 Carefully tip the monitor and chassis on one side or tip it to the left and support it 5 Remove the four scr...

Page 71: ...r to see if power is removed 2 Remove the power supply plug from the socket on the power entry panel 3 Mark and disconnect the wires between the power supply DC distribution board and multibus card ca...

Page 72: ...in the figure and disconnect the DC distribution board connector 4 Mark and disconnect the wires between the power supply and incoming AC 5 Remove the four screws holding the power supply to the cente...

Page 73: ...ry panel is used on all OIC models except the IIOIC421 tabletop Location and part numbers of the power entry panels used on the OIC consoles vary depending on the model The power entry panel contains...

Page 74: ...nel NOTES 1 Use the AC outlet for the intended purpose only 2 Refer to Section 3 for wiring and cable connections Some of the connections are on the back of the power entry panel and are accessed thro...

Page 75: ...ant breaker so that the AC line may be disconnected safely 3 Remove all cables from the front and top of the power entry panel and IIMKM02A cable Refer to Section 3 for IIOIC423 cable connections 4 Re...

Page 76: ...ly 23 kg 50 lbs IIOIC424 Panel Mount To remove the power entry panel from an IIOIC424 panel mount model see Figure 6 11 and follow these steps 1 Turn off the main circuit breaker on the power entry pa...

Page 77: ...rator and engineering keyboards mouse trackball the annunciator display panel keyboard interface assembly and the color monitor Follow all warnings and cau tions Operator and Engineering Keyboards Mou...

Page 78: ...embly is driven off the keyboard interface board and the cable is connected to the AUX PORT Unplug the cable to remove Refer to Section 3 for address switch settings IIOIC422 CONSOLE MODEL The console...

Page 79: ...ADS03 to the cabinet 4 Remove the NADS03 panel 5 Refer to Section 3 for address switch settings for new NADS03 panel 6 Install the new NADS03 panel into the cabinet 7 Install the sealing ring and ten...

Page 80: ...n the front of the power entry panel behind the front door On the Figure 6 13 NADS03 Removal from IIOIC423 Environmental Cabinet NADS03 SEALING RING RETAINING SCREWS TP80558A CAUTION On the keyboard i...

Page 81: ...Figure 6 14 Keyboard Interface Assembly IIOIC422 Model MOUSE TRACKBALL AUX 1 PORT KEYBOARD AUX KBD OFF TUNE CONFIG KEYBOARD INTERFACE ASSEMBLY FRONT VIEW KEYBOARD INTERFACE ASSEMBLY CONNECTOR BOARD TO...

Page 82: ...embly IIOIC422 CONSOLE MODEL To remove the keyboard interface assembly from an IIOIC422 console see Figure 6 15 and follow these steps 1 Turn off the main circuit breaker on the power entry panel to s...

Page 83: ...ace assembly to the power entry panel 4 Remove the keyboard interface assembly 5 Refer to Figure 6 14 for SW1 settings for the new keyboard interface assembly IIOIC424 PANEL MOUNTED MODEL To remove th...

Page 84: ...ors are used they may need to be switched to prevent damage from over voltage or under voltage A video cable connects the monitor to the monitor port on the CPU Labels R G and B represent red green an...

Page 85: ...N ADJUSTMENTS HEIGHT WIDTH BRIGHTNESS CONTRAST MONITOR DEGAUSS POWER TP80557A R REMOTE AUX 1 VGA VGA SYNC GRN CS REMOTE SCREEN CONTROLS AUX 2 AC NOT USED NOT USED NOT USED G B CS DG WARNING The monito...

Page 86: ...removing the four screws under the tray 8 Before installing a new monitor make certain the resistor switches are set to resistor to insure that the termination is set for 75 ohms and that the VGA syn...

Page 87: ...ertain the power to the console is off 2 Refer to Section 3 on panel mount installation for proce dures to remove the bezel 3 Label and disconnect all cables to or from the monitor 4 Slide the monitor...

Page 88: ...ews that fasten the CPU mounting plate to the track on each side of the cabinet 6 Slide the CPU and mounting plate completely out the rear of the cabinet 7 Place the CPU and mounting plate on a clean...

Page 89: ...6 192 5A Figure 6 17 CPU Removal for IIOIC421 Tabletop Console REAR VIEW OF MONITOR KEYBOARD INTERFACE ASSEMBLY CPU CPU MOUNTING PLATE RETAINING SCREWS REAR VIEW DOORS REMOVED TP36161C KEYBOARD PORT M...

Page 90: ...ower Check the power indicator to see if power is removed 2 Remove the AC power cable from the CPU 3 Remove and label all communication cables from the top of the CPU 4 Remove the four retaining screw...

Page 91: ...on the power entry panel Check the power indicator to see if power is removed 2 Remove the AC power cable from the CPU 3 Remove and label all communication cables from the rear of the CPU 4 Remove the...

Page 92: ...re 6 21 for connec tor callouts and to the appropriate figure in Section 3 for the cable connections for the model OIC being used Figure 6 20 CPU Removal for IIOIC424 Panel Mount Console MONITOR POWER...

Page 93: ...to the IIOIS42 instruction manual for details on printer configura tion operation and cabling requirements NOTE Port 1 of the CPU will accept either the touch screen option or a printer not both Refe...

Page 94: ...in identifying the part When ordering parts use part numbers and part descriptions from equipment manuals Parts with no commercial descrip tion must be ordered from your nearest sales or service offi...

Page 95: ...rd interface front panel IIOIC421 194776A11001 x x x x Joystick 1948803A2 x Keyboard enclosure 1948802A3 x Keyboard operator mylar 6638514A1 x x x Keyboard operator mylar 6638514A2 x Keyboard QWERTY a...

Page 96: ...0571A POWER CONNECTOR FOR IIMKM02A WHEN USED ON THE IIOIC421 IIOIC423 AND IIOIC424 NOT USED IN IIOIC422 CONNECT 8 PINS VERTICALLY DATA TRANSMITTED FROM PIN 2 RECEIVED ON PIN 3 CONNECT 8 PINS HORIZONTA...

Page 97: ...ARD NOT USED ON IIOIC421 OR IIOIC424 F1 F2 AND F3 ARE 2 A 250 V FAST BLOW TO P7 ON MKM BOARD AND TO P2 ON ADP BOARD P9 NOT USED P10 TO MOUSE PORT ON CPU CAUTION SWITCHES 5 6 AND 7 ARE CLOSED ON SWITCH...

Page 98: ...SCREEN ADJUSTMENTS HEIGHT WIDTH BRIGHTNESS CONTRAST MONITOR DEGAUSS POWER SYNCH ON GREEN SWITCH TP80574A R REMOTE AUX 1 VGA VGA SYNC GRN CS REMOTE SCREEN CONTROLS AUX 2 AC NOT USED NOT USED NOT USED G...

Page 99: ...LL VARY ACCORDING TO ADP ADS USE SW1 SETTING FOR SINGLE DISPLAY SAME FOR ALL UNITS Figure A 7 IIADP01 Multiple Annunciator Displays TP35494B TO AUX PORT ON KEYBOARD INTERFACE BOARD P1 BACK OF ADP PANE...

Page 100: ...ts 4 2 E Engineering keyboard 3 21 Cleaning 5 4 Environmental cabinet wiring 3 17 F Fan assembly card cage 6 5 Functional operation OIC 2 2 Fuses F1 keyboard interface front panel 3 7 F1 F2 F3 keyboar...

Page 101: ...ibus module IIMKM02A 6 1 Mylar keyboard cleaning 5 4 N NADS03 annunciator display panel 3 26 Nomenclature 1 7 O Observe 3 1 OIC Console operation 2 2 Hardware overview 1 1 Models 1 4 OIC description I...

Page 102: ...rd 6 19 T Tabletop adjustment console 3 9 Technical documentation 7 1 Touch screen 3 27 6 30 Controller board Connections 3 29 Installation 3 28 Switch settings 3 30 IIMKM02A jumper settings 3 29 Trac...

Page 103: ...y Wickliffe Ohio Phone 1 216 585 8500 Telefax 1 216 585 8756 Canada Elsag Bailey Canada Inc Burlington Ontario Phone 1 905 639 8840 Telefax 1 905 639 8639 Mexico Bailey Mexico S A de C V Naucalpan Pho...

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