Honeywell Enhanced Micro TDC 3000 (MT11-520) DCS Control System

Honeywell Enhanced Micro TDC 3000 (MT11-520) DCS Control System

System Introduction and Overview

System positioning

The Enhanced Micro TDC3000 is a compact DCS that communicates with process equipment through UCN (Universal Control Network) and is controlled by APM (Advanced Process Manager) for process monitoring. Basic model MX-DAB01, hardware includes K2LCN processor, 1 US universal station, APM, AM application module, and HM history module.

Attention: Dual US B version base models are no longer available; UXS and AXM hardware are not supported.

Core node components

Node Function

US universal station human-machine operation window, integrated display, keyboard, disk drive, access to process data

The AM application module completes complex calculations and special control strategies; Memory 4MW/8MW

NIM network interface module connects LCN and UCN, and interfaces with APM process controller

HM History Module Large Capacity Storage System Software, Process History, User Data

Scalable up to 8 nodes, with optional redundant NIM, additional US, PLC gateway, computer gateway, factory network module, etc.

Human computer peripherals

Operator keyboard: Thin film chemical resistant keyboard, left side keys support user-defined labels, built-in three function alarm buzzer;

Engineer keyboard: supports hot plugging, can be configured for use by engineers, can take away restricted operator advanced permissions, and can be plugged into the side interface of the operator keyboard;

TPLCN twisted pair local control network: replaces traditional coaxial LCN, RS-485 interface, 5Mbps token passing protocol, used for internal node communication between two cabinets; Optional upgrade kit to connect to standard coaxial LCN system.

Operating standards and equipment handling requirements

Before starting up: Control room dust removal, seal windows, dust-proof floor mats, eliminate static electricity hazards, and prohibit smoking; Prepare anti-static wristbands.

During operation: humidity maintained at 40-60%, humidity change rate<6% per hour; Restricting personnel access; The distance between the handheld walkie talkie and the device is ≥ 3 meters; Standardize cleaning methods and strictly prohibit liquid splashing on equipment; Regularly clean the filter screen.

Circuit board operation ESD anti-static: When disassembling and assembling the board, turn off the power, only hold the edge of the board, wear a grounding wristband, and use a conductive workbench; Boards must be stored in conductive shielding bags, and foam packaging and transportation are prohibited.

Box disk (Bernoulli) operation: Adapt the disk to the ambient temperature before use; Do not open the disk casing; Set write protection to prevent accidental deletion; The drive must be powered on before inserting or removing the disk; Determine the driver status through the panel indicator lights.

On site preparation and installation

environmental parameters

Storage conditions: Temperature -10~70 ℃, relative humidity -10~80%, avoid condensation; Only supports one-year storage period;

Operating environment: Class C office environment, working temperature 0-45 ℃, with clear anti vibration indicators;

Power supply: AC 120/240Vac (+10%/-15%), frequency 47-63Hz; equipment must be grounded together; Distinguish between North American NEMA sockets and European CEE-7 socket requirements.

Dimensions and Weight

Including electronic cabinets (Tower 1, Tower 2), APM dual access cabinets, printers, and multiple 20/21 inch displays in terms of external dimensions and weight. The APM cabinet weighs 200kg.

Layout requirement: Reserve at least 1 meter of maintenance and repair space around the equipment, with a typical minimum control room of 4m x 4m.

unboxing inspection

Open the box and inspect for transportation damage, check the packing list; It is prohibited to grab the touch screen frame and move the CRT monitor, as it may damage the touch screen.

Hardware Cabinet Description

The system includes 2 electronic cabinets (Tower # 1, Tower # 2, each with a maximum of 4 nodes, totaling a maximum of 8 nodes)

Tower # 1 (Tower 1): Comes with a dual box disk drive;

Tower # 2 (Tower 2): Built in high-capacity Winchester hard drive;

Important warning: Power on is only allowed after all installation work is completed. Before powering on, all power switches should be turned off and the power cord should be unplugged; It is recommended to use a roller cart for transporting heavy cabinets.

Wiring work

Distinguish between two sets of solutions: standard cabling and CE EMC compliant cabling. The EMC version has both ends of the outdoor cable shielding layer connected to the cabinet casing ground, and the connector casing is completely shielded.

Board Introduction

TP485 board: Implement TPLCN twisted pair network;

EPDGP/EPDGC I/O board: peripheral interface board (display, keyboard, printer, touch screen, trackball); EPDGC is the CE-EMC version, with all D-type shielded connectors.

Peripheral wiring: operator keyboard, engineer keyboard, printer, color monitor, touch screen, trackball, TPLCN cabinet interconnection cable. Touchscreen and trackball cannot be used simultaneously on the same US.

UCN process cable: connects NIM and APM process controllers; UCN channels A/B are strictly prohibited from crossing or misconnecting; The UCN tap needs to be grounded.

Option wiring: redundant NIM, computer gateway CG, EPLCG enhanced PLC gateway wiring;

LCN upgrade option kit: Connecting Micro TDC3000 to a traditional coaxial LCN system requires migrating some nodes and reallocating node addresses, which is a complex operation.

Installation completion

Secure all cable stress release buckles and reinstall the back cover; Cleaning packaging materials; Remove the disk drive transport foam; Confirm that all switches are turned off, connect the power cord, and prepare to enter the power on test.

System power on inspection

After the installation is complete, perform a power on self-test. If any faults occur, refer to Chapter 6 Maintenance.

Inspection of electronic units in Tower 1 and Tower 2

Remove the front door and confirm that the maintenance jumper LO-NOM-HI is placed in the middle position of NOM; Power on observation board LED indicator light; Normal green LED lights up, and the digital display shows the node address; The constant red light indicates a self-test failure, and a fault code is recorded; Check the power supply OK, fault ERROR, and fan alarm indicator light; Test the RESET reset button function. The HM history module automatically boots up when powered on.

Color monitor testing: power on, adjust brightness contrast, adjust display pitch angle.

Printer ASPI-41 Test:

Self testing: Press and hold ONLINE to turn on the printer, and the printer will print all character sets in a loop;

User diagnostic testing: Perform complete hardware diagnostics and print configuration reports; Record fault codes for maintenance purposes.

Box disk drive test: Insert a write protected disk and observe the yellow green LED read-write indicator light; Warning: The indicator light is flashing/constantly on, and unplugging is strictly prohibited.

All tests passed, entering Chapter 4 System Implementation Configuration; Perform troubleshooting if there is a malfunction.

System implementation configuration

Implementation includes system startup, network database, UCN/APM points, screens, logs, buttons, and Area database configuration; You can directly load the factory precompiled configuration file or configure it from scratch. We need an engineer keyboard.

System startup and LCN network configuration (NCF network configuration file)

Two modes: loading factory pre made NCF files, or fully manual configuration; The system supports adding nodes online to CG computer gateway and EPLCG PLC gateway.

Guide the US universal station: Power off and restart the cabinet, perform a LOAD boot on the operator keyboard, select UNP (universal personality, switchable operator/engineer mode) or OPR (operator mode only); Set the system time and date, and verify that the HM history module status must be OK.

Pre configured NCF includes a complete set of system parameters such as unit, region, console, node parameters, alarm policies, access permission tables, disk volume configuration, continuous history, log parameters, and print report parameters.

Loading of various modules (AM, NIM, APM, gateway)

AM application module: manual cold/hot loading, can use default HM data source, or use empty checkpoint (&C8 tape) without loading pre fabricated points;

NIM network interface module (main NIM # 3, redundant NIM # 4): loads operator program; Define the correspondence between NIM and APM for prefabricated UCN entities;

APM Advanced Process Manager loading: loading programs, restoring data; Support standard double-sided non redundant cabinets and extended I/O cabinets; The document provides a chart of APM cabinet IOP card locations;

EPLCG/CG gateway loading: Use empty checkpoint tape&C8.

Data point establishment

The system comes with pre fabricated AM and APM process points, which are stored in Appendix A. The DEB data entity generator can be used to create, modify, and delete measurement points.

Custom Function Configuration

Picture Editor: Creating process flow diagrams;

Free Format Logs: Customize printing reports;

Button Configuration: Custom keys for the operator keyboard, pre made configuration file BUTTON01 (Appendix B);

User CL control language program: CL/AM runs in the application module; CL/APM running in APM; Write, compile, link, and load user control programs.

Area Database Configuration

Factory prefabricated AREA01 regional database; Define unit allocation, group display, trends, alarms, logs, and reports; After the modification is completed, execute INSTALL ARE to install the database and make it effective. After completing all configurations, switch the US to the operator personality and put the system into operation.

Operation Guide

Two types of operational personalities

UNP Universal Personality: a set of system switching engineer configurations, operator monitoring, 6MB memory US support;

OPR Operator Personality: Only for process monitoring and cannot modify configurations.

Loading method: ① Local tape boot; ② Remote loading of other stations with already running US; ③ HM hard drive auto boot. Set the time and date after the system startup is completed.

Module daily loading operation

After the US is running, load AM, NIM, APM, HM, and gateway through the System Status screen; HM factory configuration supports automatic power on bootstrap. After the UCN device is loaded, STARTUP needs to be executed to start APM.

Daily operation call screen

Detail Display: Enter the point ID to view the measurement point;

Group Display: Call the measurement point group; Standard screens for system status, alarms, trends, etc., refer to the Process Operations Manual.

Access permission key lock (KEYLOCK)

The Micro TDC3000 does not have a hardware key switch and relies on a password screen to achieve three levels of permissions: operator OPER, supervisor SUPV, and engineer ENGR. Factory password: TDC3000 SUPV, TDC3000 ENGR. You can use a visual editor to change the password; Call the permission interface through the KEYLOCK flowchart screen; The console status screen allows you to view the current actual access level.

Display operation

Supports three 21 inch CRT monitors: IDEK MF-5221 (analog knob), IDEK MF-8221 (numeric buttons), and Hitachi HM-4821-D (CE compliant). The document provides detailed instructions on brightness, contrast, geometric distortion, demagnetization DEGAUSS, and BNC video input impedance settings. Simultaneously provide a comparison table of touch screen accessory models.

Maintenance and Service

On site adjustment: LCN node address jumper, UCN node jumper, 21 inch display hardware adjustment;

Cleaning and maintenance: disassembly and cleaning of air filters, cleaning process of keyboards, monitors, and printers;

Troubleshooting: The HVTS hardware verification testing system is used for hardware diagnosis; Spare parts description.