ProcessLogix Battery Extension Module

Transcription

1 Installation Instructions ProcessLogix Battery Extension Module Cat. No BEM This document explains how to install the Battery Extension Module (1757-BEM) into the ProcessLogix System. Topic Page Important User Information 2 North American Hazardous Location Approval BEM Functionality 6 Self Test Circuitry 6 RIUP Support 7 Available Battery Power 7 Recommended Configuration 8 Battery Pack 7 Switchover Circuitry 8 Understanding the Electrical Design 8 Installing the Battery into the Battery Extension Module 10 Determining the 1757-BEM Chassis Slot Location 11 Installing the 1757-BEM into the Chassis 12 Wiring the 1757-BEM Status Connector 13 Specifications 14 Rockwell Automation Support Backcover

2 2 ProcessLogix Battery Extension Module Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT ATTENTION SHOCK HAZARD Identifies information that is critical for successful application and understanding of the product. Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence Labels may be located on or inside the module to alert people that dangerous voltage may be present. BURN HAZARD Labels may be located on or inside the module to alert people that surfaces may be dangerous temperatures.

3 ProcessLogix Battery Extension Module 3 North American Hazardous Location Approval The following information applies when operating this equipment in hazardous locations: Products marked CL I, DIV 2, GP A, B, C, D are suitable for use in Class I Division 2 Groups A, B, C, D, Hazardous Locations and nonhazardous locations only. Each product is supplied with markings on the rating nameplate indicating the hazardous location temperature code. When combining products within a system, the most adverse temperature code (lowest T number) may be used to help determine the overall temperature code of the system. Combinations of equipment in your system are subject to investigation by the local Authority Having Jurisdiction at the time of installation. WARNING EXPLOSION HAZARD Do not disconnect equipment unless power has been removed or the area is known to be nonhazardous. Do not disconnect connections to this equipment unless power has been removed or the area is known to be nonhazardous. Secure any external connections that mate to this equipment by using screws, sliding latches, threaded connectors, or other means provided with this product. Substitution of components may impair suitability for Class I, Division 2. If this product contains batteries, they must only be changed in an area known to be nonhazardous. Informations sur l utilisation de cet équipement en environnements dangereux : Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne conviennent qu à une utilisation en environnements de Classe I Division 2 Groupes A, B, C, D dangereux et non dangereux. Chaque produit est livré avec des marquages sur sa plaque d identification qui indiquent le code de température pour les environnements dangereux. Lorsque plusieurs produits sont combinés dans un système, le code de température le plus défavorable (code de température le plus faible) peut être utilisé pour déterminer le code de température global du système. Les combinaisons d équipements dans le système sont sujettes à inspection par les autorités locales qualifiées au moment de l installation. AVERTISSEMENT RISQUE D EXPLOSION Couper le courant ou s assurer que l environnement est classé non dangereux avant de débrancher l'équipement. Couper le courant ou s'assurer que l environnement est classé non dangereux avant de débrancher les connecteurs. Fixer tous les connecteurs externes reliés à cet équipement à l'aide de vis, loquets coulissants, connecteurs filetés ou autres moyens fournis avec ce produit. La substitution de composants peut rendre cet équipement inadapté à une utilisation en environnement de Classe I, Division 2. S assurer que l environnement est classé non dangereux avant de changer les piles.

4 4 ProcessLogix Battery Extension Module IMPORTANT The Control Processor contains a non-rechargeable lithium battery (catalog no PLXBAT) that provides memory backup time of 6 days (with a fully-charged battery). Ideally, you should remove the lithium battery when a 1757-BEM (NI-CD) is also present (to prevent it from being needlessly depleted), but both may be present in the controller chassis. If both batteries are present, the BAT LED will turn red instead of green when the CPM goes through startup diagnostics and enters the IDLE state. WARNING Battery Handling When you connect or disconnect the battery an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. For Safety information on the handling of lithium batteries, such as the 1757-PLXBAT, including handling and disposal of leaking batteries, see Guidelines for Handling Lithium Batteries, publication AG 5-4. WARNING If you connect or disconnect wiring while the field-side power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Removal and Insertion Under Power (RIUP): When you insert or remove the module while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Repeated electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance that can affect module operation. Removable Terminal Blocks (RTB) for I/O connections: When you connect or disconnect the Removable Terminal Block (RTB) with field side power applied, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

5 ProcessLogix Battery Extension Module 5 ATTENTION Environment and Enclosure This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC publication ), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as open type equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to pr event personal injury resulting from accessibility to live parts. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the Allen-Bradley publication ( Industrial Automation Wiring and Grounding Guidelines ), for additional installation requirements pertaining to this equipment. ATTENTION Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: Touch a grounded object to discharge potential static. Wear an approved grounding wriststrap. Do not touch connectors or pins on component boards. Do not touch circuit components inside the equipment. If available, use a static-safe workstation. When not in use, store the equipment in appropriate static-safe packaging.

6 6 ProcessLogix Battery Extension Module 1757-BEM Module Features 1757-BEM Functionality The main function of the 1757-BEM (Battery Extension Module) is to provide battery backup power for volatile memory IC's contained within a module, such as the 1757-PLX52. The battery backup is useful for maintaining information (such as configuration databases) during temporary power outages and weekend shutdowns. The 1757-BEM is a separate, single-wide module that plugs into the ProcessLogix Controller chassis. It incorporates the standard ICP plastic module cover and front door. Connection to the backplane is via the standard ICP connector. The Battery Extension Module ships with one battery un-installed. Three (3) series-connected, sub-c size, nickel-cadmium cells makeup the battery pack. The sourcing capacity is rated at 200mAh. The BEM provides 5 milliamps of DC current at 3.6 volts for a period of 240 hours on a full charge. This rating includes - in addition to actual memory power - any current drawn by the support electronics. Self Test Circuitry The self-test circuitry on the BEM does the following: periodically tests for battery pack presence periodically tests the battery pack under load These tests are performed only when primary Controller power is present. Local indication of the state (health) of the battery system is provided via an indicator on the front cover along with the capability for external/remote alarming in the event of battery deterioration or failure.

7 ProcessLogix Battery Extension Module 7 RIUP Support You can insert and remove the 1757-BEM while under power, i.e., supports RIUP. The battery pack is accessible only when the module is out of the chassis. WARNING If you connect or disconnect wiring while the field-side power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Removal and Insertion Under Power (RIUP): When you insert or remove the module while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Repeated electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance that can affect module operation. Removable Terminal Blocks (RTB) for I/O connections: When you connect or disconnect the Removable Terminal Block (RTB) with field side power applied, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Available Battery Power Battery power is available to all slots in the chassis via pin D14 on the ICP backplane. In theory, the number of sink modules allowed in one chassis is limited only by the number of slots in a given chassis. Keep in mind that the module will supply at most 1200mAh. For two modules, each drawing 5mA, the BEM will be able to maintain the memory contents of the two modules throughout one weekend (5PM Fri. to 8AM Mon.). Battery Pack The battery pack is a prefabricated unit consisting of three, series-connected, high temperature, sub-c size NiCd cells, shrink-wrapped, with a 2-wire harness to a polarized plastic connector. The advantages of this approach are: easier handling than multiple, loose batteries eliminates the possibility of unintentionally reversed installation provides easy method for disconnecting the battery for shipping and storage A battery pack is shipped with every 1757-BEM unit but the battery pack does not come installed in the unit. You must install the battery pack as part of the module installation.

8 8 ProcessLogix Battery Extension Module Recommended Configuration There are no restrictions on the number of 1757-BEMs that may reside in a given chassis. This gives the user an option for increasing backup capacity. Also, coupled with RIUP, this facilitates continued backup protection in the event a 1757-BEM must be removed from the rack. The recommended configuration is to have one BEM unit for each module requiring memory backup power. This ensures that enough battery capacity is available for extended periods of time, such as a four day Thanksgiving weekend. Battery voltage is unregulated on the 1757-BEM. Sink modules must provide surge limiting to prevent voltage dips if they are installed with the controller power off - i.e., while the battery pack is supplying power. Sink modules should also be prepared to withstand voltage dips potentially caused by other modules. Battery power is protected on the 1757-BEM against damaging current drain rates. Switchover Circuitry There is no switchover circuitry on the 1757-BEM. Switchover to battery power is accomplished on the sink module(s). The switchover circuitry must be designed so that it does not impose a surge on the battery pack when the sink modules are installed under power (i.e., it must recognize chassis power before battery power) to protect against nuisance low battery alarms. Understanding the Electrical Design Charge Control The battery charging circuit is a quasi-constant current, trickle charge design. Constant current is the preferred method for charging NiCd batteries. Quasi-constant current is a simplified variant. It is accomplished by making the charging source voltage much greater than the battery voltage and limiting the current flow with a series resistance. The series resistance value is large compared to battery internal resistance (usually a fraction of an ohm), hence making the effect of battery voltage changes less significant to circuit operation. The current becomes relatively constant with respect to small battery voltage changes (as the battery charges) and source voltage variation. In trickle charge, the battery is continuously charged at a very low rate. A NiCd cell, when left open circuit for long periods of time, will gradually lose charge or capacity. A trickle charge replenishes these losses (and recharges a spent battery). The trickle current for the BEM is 40mA. This provides for a 1/30 capacity charge rate for 1200mAh cells. Charger power is drawn from the +24 VDC main supply. The battery pack is connected to the charging power supply with the load in parallel. Normally, power flows from the DC source to the load, but when power is interrupted from the main source, power is discharged from the battery. A blocking diode in series with the charging source prevents back-flow of battery current into the +24 VDC plane.

9 ProcessLogix Battery Extension Module 9 A settable, positive temperature coefficient (PTC) overcurrent protection device in series with the load safeguards the battery pack against excessive current drain. Test Control Two tests are routinely performed on the battery: battery present and battery load. The battery present test is a simple (unloaded) check that a battery is present. It is run at relatively frequent intervals of once every 8.5 seconds. At less frequent intervals, the battery load test presents a load to the battery sufficient to provide a level of confidence that the battery is healthy. A load of 350mA is applied to the battery for a short period of 8.5 seconds at intervals of once every 73 minutes. Precautions are taken such that the test load is removed from the battery circuit if main power fails while the test is in progress. During the battery tests, charger voltage must be removed temporarily from the battery circuit. A 'window' voltage comparator then detects the actual battery voltage below a minimum level of 3.0 volts, as well as above a maximum level of 4.6 volts. Display and Alarm One LED, visible through the front cover of the 1757-BEM, provides you status information. The LED is labeled OK and indicates the health of the internal battery pack. This BATTERY OK LED is a dual color red/green LED driven from the output of the battery window voltage comparator. When the LED is green the battery voltage is within the acceptable level. When the LED is red the battery voltage falls outside the acceptable range. Attach the external and/or remote alarm(s) through screw terminals accessible through the front door of the 1757-BEM. These terminals are connected to the normally-opened and normally-closed contacts of a relay that is driven from the output of the battery window voltage comparator. The relay NO contacts are closed if the battery voltage is within the acceptable level ( vdc). The relay NO contacts are open if the battery voltage falls outside the acceptable range.

10 10 ProcessLogix Battery Extension Module Installing the Battery into the Battery Extension Module 1. Remove the screws securing the cover to the Battery Extension Module. Left side view Remove the screws 2. Remove the module cover. Remove the screws Bottom view 3. Insert the battery into the battery holder. Left side view

11 ProcessLogix Battery Extension Module Connect the battery cable to the port. Left side view Connect the battery cable to the port 5. Reinstall the cover and replace the two screws removed in step 1. Determining the 1757-BEM Chassis Slot Location Be sure to place the 1757-BEM module in the recommended slot according to the table below. Table BEM Chassis Slot Location If your chassis is this size: 7 or 13 slot chassis slot 6 10 or 17 slot chassis slot 4 Install 1757-BEM in this slot:

12 12 ProcessLogix Battery Extension Module Installing the 1757-BEM into the Chassis 1. Position the module at the correct chassis slot as instructed in the table. 2. Align the module s circuit board with the top and bottom chassis guides. 3. Slide the module into the chassis until the module tabs click into position.

13 ProcessLogix Battery Extension Module 13 Wiring the 1757-BEM Status Connector The 1757-BEM is supplied with a connector (in the spare parts bag). You must wire the connector, then install it. 1. Locate the connector in the spare parts bag shipped with the module. 2. Insert the appropriate wiring and tighten the screws. Terminals 1 and 2 provide a normally-open relay contact. Terminals 3 and 4 provide a normally-closed relay contact. For relay contacts performance rates for resistive loads, refer to the Controller Redundancy Specification in the publication 1757-IN N.O. N.O. N.C. N.C. Digital I/O annunciator or other device 3. Install the connector into the 1757-BEM. Left side view Re-install the connector

14 14 ProcessLogix Battery Extension Module Specifications Specification Description Electrical backplane current 5.1 V 112 ma 24 V 36 ma power dissipation thermal dissipation sourcing capacity watts 9.6 watts 200mAh Physical module size ICP std. 1 slot wide Alarm Relay Contact chassis location (recommended default) weight mounting Enclosure Type Rating voltage/current ratings Channels ground isolation recommended default: slot 6 in 7 or 13-slot slot 4 in 10 or 17 slot 0.35 kg 35 mm DIN rail None (open-style) 30 v dc maximum / 100 milliamps maximum one 30 V Environmental Enclosure Type Rating None (open-style) Operating Temperature Storage Temperature Relative Humidity Vibration Shock Emissions 0 to 60 C (32 to 140 F) IEC (Test Ad, Operating Cold), IEC (Test Bd, Operating Dry Heat), IEC (Test Nb, Operating Thermal Shock) 40 to 85 C ( 40 to 185 F) IEC (Test Ab, Un-packaged Non-operating Cold), IEC (Test Bb, Un-packaged Non-operating Dry Heat), IEC (Test Na, Un-packaged Non-operating Thermal Shock) 5 to 95% non-condensing IEC (Test Db, Un-packaged Non-operating Damp Heat) IEC (Test Fc, Operating): Hz IEC (Test Ea, Unpackaged shock): Operating 30g Non-operating 50g CISPR 11: Group 1, Class A ESD Immunity IEC : 4kV contact discharges 8kV air discharges Radiated RF Immunity EFT/B Immunity IEC : 10V/m with 1kHz sine-wave 80%AM from 30MHz to 1000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz IEC : ±2kV at 5kHz on signal ports

15 ProcessLogix Battery Extension Module 15 Specification Surge Transient Immunity Conducted RF Immunity Magnetic Field Immunity Power Requirements Certifications (when product is marked) Description IEC : ±1kV line-line(dm) and ±2kV line-earth(cm) on signal ports IEC : 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz IEC : 30A/m at 50Hz 11-30V dc; V dc (typical) UL CSA CSA FM CE (1) C-Tick (1) UL Listed Industrial Control Equipment CSA Certified Process Control Equipment CSA Certified Process Control Equipment for Class I, Division 2 Group A,B,C,D Hazardous Locations FM Approved Equipment for use in Class I Division 2 Group A,B,C,D Hazardous Locations European Union 89/336/EEC EMC Directive, compliant with: EN ; Industrial Emissions EN ; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN ; Industrial Immunity Australian Radio-communications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions (1) See the Product Certification link at for Declarations of Conformity, Certificates, and other certification details.

16 Rockwell Automation Support Rockwell Automation provides technical information on the web to assist you in using our products. At you can find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. For an additional level of technical phone support for installation, configuration and troubleshooting, we offer TechConnect Support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your module up and running: United States Monday Friday, 8am 5pm EST Outside United States Please contact your local Rockwell Automation representative for any technical support issues. New Product Satisfaction Return Rockwell tests all of our products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned: United States Outside United States Contact your distributor. You must provide a Customer Support case number (see phone number above to obtain one) to your distributor in order to complete the return process. Please contact your local Rockwell Automation representative for return procedure. PN Supersedes Publication 1757-IN520A-EN-P, 1757-IN093A-US-P, May 2000, March 1999 Copyright 2004 Rockwell Automation, Inc. All rights reserved. Printed in the