Instruction manual

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Remote Automation Solutions

Part Number D301217X012

July 2014

ROC800-Series Remote Operations Controller

Instruction Manual

ROC809

ROC827

Summary of content (181 pages)

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Part Number D301217X012 July 2014 ROC800-Series Remote Operations Controller Instruction Manual ROC809 ROC827 Remote Automation Solutions
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ROC800-Series Instruction Manual Revision Tracking Sheet July 2014 This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover.
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ROC800-Series Instruction Manual Contents Chapter 1 – General Information 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 Scope of Manual ........................................................................................................................... 1-2 Series 1 versus Series 2 Architecture ........................................................................................... 1-3 Hardware......................................................................................................
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ROC800-Series Instruction Manual 2.8 2.7.1 Installing a License Key ..................................................................................................... 2-19 2.7.2 Removing a License Key ................................................................................................... 2-19 Startup and Operation .................................................................................................................... 2-20 2.8.1 Startup ...........................................
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ROC800-Series Instruction Manual 5.5.1 Using the LOI ....................................................................................................................... 5-7 Ethernet Communication .............................................................................................................. 5-7 EIA-232 (RS-232) Serial Communication ..................................................................................... 5-9 EIA-422/485 (RS-422/485) Serial Communications Module ...............
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ROC800-Series Instruction Manual Chapter 1 – General Information This manual focuses on the hardware aspects of the ROC809 and ROC827 Remote Operations Controllers – also known as the ROC800Series controllers (“ROC800”) – and the ROC800-Series expansion backplanes (“EXPs”), that attach only to the ROC827 and provide increased I/O capabilities. For technical information on the ROC800s, refer to the technical specifications ROC800:800, and ROC800:FW1 (available at www.EmersonProcess.com/Remote).
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ROC800-Series Instruction Manual 1.5.2 Meter Runs and Stations ...................................................................... 1-16 1.5.3 ROC800 Flow Calculations ................................................................... 1-16 1.5.4 ROC800L Flow Calculations ................................................................. 1-17 1.5.5 Automatic Self Tests ............................................................................. 1-17 1.5.6 Low Power Modes ..................................
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ROC800-Series Instruction Manual 1.2 Series 1 versus Series 2 Architecture The Series 2 ROC800 architecture incorporates a redesigned CPU module and redesigned expansion I/O backplanes to provide major system advancements. These include an increase in processor speed (from 50MHz to 65MHz), an increase in SRAM for User C programs (20K to 100K), an increase in flash memory (4Mb to 16Mb), an increase in DRAM (8Mb to 16Mb), and greater general flexibility in module placement.
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ROC800-Series Instruction Manual Module DI HART HART-2 DO DOR RTD TC TC2 PI IEC 62591 NRM AC I/O APP485 ROC809 Series 1 CPU Any Any None Any Any Any Any None Any None None Any Any ROC809 Series 2 CPU Any Any 4 Any Any Any Any None 5 Any Any Any 1st three slots Any Any Module Color Grey Grey Black Grey Grey Grey Grey Black Grey Black Black Grey Black 1 With firmware version 2.13 or greater With firmware version 2.10 or greater 3 The ROC809 supports a maximum of two MVS modules 4 With firmware version 3.
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ROC800-Series Instruction Manual Note: For further information, refer to the technical specification ROC800. For further information on compatibility and migration issues, refer to the Remote Automation Solutions Technical Support White Paper WP0800004R1. 1.3 Hardware The ROC809 and ROC827 are highly innovative and versatile units with an integrated backplane to which the central processor unit (CPU), power input module, communication modules, and I/O modules connect.
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ROC800-Series Instruction Manual A F B G C H D E A B C D E F G H Power Supply Module CPU LOI (Local Port) EIA-232 (RS-232D) Built-in Ethernet (Comm1) Built-in EIA-232 (RS-232C) (Comm2) Module (1 of 9 max) Wire Channel Cover Right End Cap Figure 1-1. ROC809 Module Placement The left-most slots in the ROC809 (Figure 1-1) accommodate the Power Input module and the CPU module. The remaining nine slots can accommodate either communication modules or I/O modules (see Table 1-1).
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ROC800-Series Instruction Manual A F B G C H D E A B C D E F G H Power Supply Module CPU LOI (Local Port) EIA-232 (RS-232D) Built-in Ethernet (Comm1) Built-in EIA-232 (RS-232C) (Comm2) Module (1 of 27 max) Wire Channel Cover Right End Cap Figure 1-2.
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ROC800-Series Instruction Manual Communication Ports and Modules The ROC800 provides up to six communication ports (refer to Chapter 5, Communications). Three communication ports are built-in:    Local Operator Interface (LOI) – Local Port EIA-232 (RS-232D). Ethernet – Comm1 Port for use with the DS800 Development Suite Software. EIA-232 (RS-232C) – Comm2 Port for point-to-point asynchronous serial communications.
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ROC800-Series Instruction Manual 1.3.1 Central Processor Unit (CPU) The CPU contains the microprocessor, the firmware, connectors to the backplane, the three built-in communication ports (two with LEDs), a LED low power wakeup button, a RESET button, the application license key connectors, a STATUS LED indicating system integrity, and the main processor. CPU components include:           32-bit Motorola MPC862 Quad Integrated Communications Controller (PowerQUICC) PowerPC processor.
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ROC800-Series Instruction Manual Table 1-3.
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ROC800-Series Instruction Manual 1.4 FCC Information This equipment complies with Part 68 of the FCC rules. Etched on the modem assembly is, among other information, the FCC certification number and Ringer Equivalence Number (REN) for this equipment. If requested, this information must be provided to the telephone company. This module has an FCC-compliant telephone modular plug.
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ROC800-Series Instruction Manual Note: To convert a ROC800 to a ROC800L, refer to the ROC800L Field Conversion Guide (Part Number D301683X012 ). The ROC800-Series Operating System firmware provides a complete operating system for the ROC800. The firmware in the ROC800 is field-upgradeable using a serial connection or the Local Operator Interface (LOI) local port.
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ROC800-Series Instruction Manual database point to be one of the possible types of points available to the system. Together, these three components—the type (T), the logical (L), and the parameters (P)—can be used to identify specific pieces of data that reside in a ROC800’s data base. Collectively, this three-component address is often called a “TLP.
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ROC800-Series Instruction Manual log-on ID supplied to the ROCLINK 800 software must match one of the IDs stored in the ROC800. The operating system firmware supports the application-specific firmware supplied in the Flash ROM.
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ROC800-Series Instruction Manual Slot Number 18 19 20 21 22 23 24 25 26 27 ROC800L Logicals (16 pt) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Logicals (8 pt) 144–151 152–159 160–167 168–175 176–183 184–191 192–199 200–207 208–215 216–223 The ROC800L firmware provides many of the same capabilities as the ROC800 firmware. We recommend, however, that the ROC800L supports only six gas runs (using a single AGA key). History stored in firmware is limited to measurements from gas meter runs, rather than liquids.
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ROC800-Series Instruction Manual view the logs, save them to a disk file, or print them using ROCLINK 800 software. ROC800L To accommodate NIST Handbook 44 (HB 44) requirements, the firmware in the ROC800L tracks up to 1000 weights and measures (W&M) events. 1.5.2 Meter Runs and Stations You can group similarly configured meter runs into stations, which provide great benefits during configuration and reporting.
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ROC800-Series Instruction Manual The AGA 8 method calculates the compressibility factor based on the physical chemistry of the component gasses at specified temperatures and pressures. The firmware supports liquid calculation methods ISO 5167 and API 12. You must supply factors for API 12 correction through a Function Sequence Table (FST) or user program. For more information, refer to the Function Sequence Table (FST) User Manual (Part Number D301058X012).
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ROC800-Series Instruction Manual     Voltage tests (battery low and battery high) ensure the ROC800 has enough power to run. The ROC800 operates with 12 Volts dc (nominal) power provided either through a PM-12 or PM-24 power input module (see Figures 3-1 or 3-2). The LED at the top of each module lights when you apply input power with the proper polarity and startup voltage. For the PM-12 module, apply 9.00 to 11.
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ROC800-Series Instruction Manual of 10.1V), the PM-12 module ceases to provide power to the backplane. Thus, the module shuts down CPU operations. For the PM-24 and PM-30 modules, when power falls below the LoLo alarm point, the CPU goes into sleep mode. In sleep mode, the backplane still receives power, the DO modules continue to hold their logic, but nothing controls I/O at this point.
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ROC800-Series Instruction Manual bytes. Since the total amount of memory each FST uses is based on the number of steps and the commands used in each step and since different commands consume different amounts of memory, estimating the memory usage of an FST is difficult. Only after compiling an individual FST can you conclusively know its memory usage. For further information on FSTs, refer to the Function Sequence Table (FST) User Manual (Part Number D301058X012). 1.
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ROC800-Series Instruction Manual Figure 1-3. ROCLINK 800 Dynamic Graphical Interface You can build custom displays for the ROC800 that combine both graphic and dynamic data elements. The displays can monitor the operation of the ROC800 either locally or remotely. You can archive historical values for any numeric parameter in the ROC800.
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ROC800-Series Instruction Manual Use ROCLINK 800 to:            1.7 Configure and view Input/Output (I/O) points, flow calculations, meter runs, PID control loops, system parameters, and power management features. Retrieve, save, and report historical data. Retrieve, save, and report events and alarms. Perform five-point calibration on AI, RTD, and Multi-Variable Sensor MVS) inputs. Implement user security. Create, save, and edit graphical displays.
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ROC800-Series Instruction Manual  Batch Queuing: Sequences future batches, if appropriate for your organization. Used in conjunction with the batching program. Note: The integrity of metrology results is critical to the measurement aspects of the ROC800L. You can lock certain configuration parameters to ensure the accuracy of liquid hydrocarbon calculations. 1.8 DS800 Development Suite Software DS800 Development Suite software allows you to program in any one of the five IEC 61131-3 languages.
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ROC800-Series Instruction Manual 1.9 Expansion Backplane The expansion backplane is a key component to the ability of the ROC827 to expand its I/O capabilities to meet your needs. The ROC827 base unit can accommodate up to four additional expansion backplanes, which easily snap together. This increases the total number of available I/O slots to 27. Refer to Chapter 2, Installation and Use, for instructions on adding backplanes to the ROC827 base unit.
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ROC800-Series Instruction Manual Chapter 2 – Installation and Use This chapter describes the ROC800-Series housing (case), backplane (electronic connection board at the back of the housing), CPU (central processing unit), and the expansion backplane (EXP). This chapter provides a description and specifications of these hardware items and explains installation and startup of the ROC800-Series. In This Chapter 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.1 Installation Requirements .............................
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ROC800-Series Instruction Manual 2.1.1 Environmental Requirements Always install the ROC800 in a user-supplied building or enclosure to protect it from direct exposure to rain, snow, ice, blowing dust or debris, and corrosive atmospheres. If you install the ROC800 outside of a building, it must be placed in a National Electrical Manufacturer’s Association (NEMA) 3 or higher rated enclosure to ensure the necessary level of protection.
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ROC800-Series Instruction Manual  The site must comply with class limits of Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) The device may not cause harmful interference, and (2) the device must accept any interference received, including interference that may cause undesired operation. 2.1.3 Compliance with Hazardous Area Standards The ROC hazardous location approval is for Class I, Division 2, Groups A, B, C, and D.
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ROC800-Series Instruction Manual 2.1.4 Power Installation Requirements Be sure to route power away from hazardous areas, as well as sensitive monitoring and radio equipment. Local and company codes generally provide guidelines for installations. Adhere rigorously to all local and National Electrical Code (NEC) requirements. The removable terminal blocks accept 12 to 22 American Wire Gauge (AWG) wiring.
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ROC800-Series Instruction Manual Proper grounding of the ROC800 helps to reduce the effects of electrical noise on the ROC800’s operation and protects against lightning. Install a surge protection device at the service disconnect on DC voltage source systems to protect against lightning and power surges for the installed equipment. All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with a ground system tester.
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ROC800-Series Instruction Manual 2.3.1 Removing and Replacing End Caps Normal use and maintenance of the ROC800 does not typically require you to remove the end caps on the housing. Follow these procedures in case removal is necessary. To remove the end caps: 1. Place the tip of a flat-blade screwdriver into the top pry hole of the end cap and loosen the end cap by pulling the handle of the screwdriver away from the backplane. Note: The pry holes are located on the sides of the end caps. 2.
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ROC800-Series Instruction Manual 2.3.3 Removing and Installing Module Covers Before you insert an I/O or communications module, remove the module cover over the empty module slots in which you intend to install the modules. Although you are not required to remove the power to the ROC800 to perform this procedure, caution is always advisable when working with a powered ROC800.
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ROC800-Series Instruction Manual Figure 2-1. Side View of the ROC800 Figure 2-2. Bottom View of the ROC800 Note: The distance from the mounting panel to the front of the ROC800 is 174mm (6.85”). If you mount the ROC800 inside an enclosure and want to connect a cable to the LOI or Ethernet port, ensure adequate clearance for the cable and the enclosure door. For example, a molded RJ-45 CAT 5 cable can increase the clearance requirement for the enclosure by 25mm (1”).
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ROC800-Series Instruction Manual A B B A B DIN Rail Catch DIN Rail Mount Figure 2-3. Back View of the ROC800 2.4.1 Installing the DIN Rail To install the ROC800 using the 35 x 7.5 mm DIN rails: 1. Mount the lower DIN rail onto the enclosure panel. 2. Snap the upper DIN rail into the ROC800 upper DIN rail mounting blocks. 3.
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ROC800-Series Instruction Manual  ROC809: Two catches.  ROC827: One catch.  ROC827 and one EXP: Place catches on ROC827 and EXP.  ROC827 and two EXPs: Place catches on ROC827 and second EXP.  ROC827 and three EXPs: Place catches on ROC827 and third EXP.  ROC827 and four EXPs: Place catches on ROC827 and second and fourth EXP. 2.4.
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ROC800-Series Instruction Manual Removing the backplane from the housing is not recommended, as there are no field serviceable parts. If the backplane requires maintenance, please contact your local sales representative. 2.5.1 Attaching an Expansion Backplane To attach an EXP to an existing ROC827 base unit or to another EXP: 1. Remove power from the ROC827. 2. Remove the right-hand end cap from the ROC827 as described in Section 2.3.1, Removing and Replacing End Caps.
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ROC800-Series Instruction Manual 2.5.2 Removing an Expansion Backplane Note: Before you remove an EXP, you must power down the ROC827, disconnect all wiring from all modules, and remove the entire unit from the DIN rail. Once the entire ROC827 is free of the DIN rail, you can detach an individual EXP. To remove an EXP from an existing ROC827 base unit: 1. Remove the right-hand end cap from the EXP as described in Section 2.3.1, Removing and Replacing End Caps. 2.
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ROC800-Series Instruction Manual 4. Using a flat-bladed screwdriver, gently pry the plastic locking clips at the upper and lower back edge of the EXP housing away from their securing tabs. Note: Applying too much pressure breaks the plastic hooks. 5. Once you free the plastic locking clips from their securing tabs, gently pivot the back of the EXP away from the ROC827. Note: The EXP detaches quickly. Hold it securely to prevent it from falling. 6. Place the detached EXP in a secure location. 7.
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ROC800-Series Instruction Manual 1. Remove power from the ROC800. 2. Remove the CPU module from the ROC800. 3. Move the J3 jumper on the CPU module to the two lower pins. 4. Reinstall the CPU module. 5. Power up the ROC800; the backup battery is fully functional. You can disable this battery backup on the Series 2 CPU module by moving the J3 jumper (located on the CPU module) to the two upper pins (see Figure 2-8).
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ROC800-Series Instruction Manual Series 1 CPU (Green) Series 2 CPU (Black) A B C D H H E F I G A B C D E F G H I Battery LED Button RJ-45 Port License Keys RESET Button RJ-45 Port RS-232 Port Microprocessor Battery backup jumper Figure 2-8. CPU Connectors (Series 1 and Series 2 CPU Modules) Table 2-1.
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ROC800-Series Instruction Manual internal Analog to Digital Converter (A/D). The A/D monitors the supply voltage and board temperature (refer to “Automatic Self-Tests” in Chapter 1, General Information). The CPU has two buttons, LED and Reset (see Figures 2-7 or 2-8):  RESET: o To reset all comm ports, stop user programs, stop FSTs, and stop DS800 programs, press and hold in the Reset button for approximately 10 seconds while the ROC800 is powered. Note: This feature is not available on the DL8000.
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ROC800-Series Instruction Manual the default setting of five minutes, all LEDs turn off after five minutes. If you press the LED button, LEDs light and stay lit again for five minutes. By entering a 0 (zero), the LED always stays lit. 2.6.1 Removing the CPU Module Caution Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations.
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ROC800-Series Instruction Manual 2. Press the CPU firmly into the slot, ensuring the ejector clips rest on the module rail guides. The connectors at the back of the CPU module fit securely into the connectors on the backplane. 3. Place the CPU faceplate on the CPU. 4. Tighten the two screws on the faceplate of the CPU module firmly (see Figure 2-7). 5. Replace the wire channel cover. 6. Review Restarting the ROC800 in Chapter 6, Troubleshooting. 7. Return power to the ROC800 unit. 2.
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ROC800-Series Instruction Manual 2.7.1 Installing a License Key Caution Failure to exercise proper electrostatic discharge precautions (such as wearing a grounded wrist strap) may reset the processor or damage electronic components, resulting in interrupted operations. When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures.
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ROC800-Series Instruction Manual To remove a license key: 1. Perform the backup procedure described in Preserving Configuration and Log Data in Chapter 6, Troubleshooting. 2. Remove power from the ROC800. 3. Remove the wire channel cover. 4. Unscrew the captive screws from the CPU faceplate and remove it. 5. Remove the license key from the appropriate terminal slot (P2 or P3) in the CPU (refer to Figure 2-8). 6. Replace the CPU faceplate and tighten the two captive screws.. 7.
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ROC800-Series Instruction Manual indicator should light green to indicate that the applied voltage is correct. Then, the STATUS indicator on the CPU should light to indicate a valid operation. Depending on the Power Saving Mode setting, the STATUS indicator may not remain lit during operation (refer to Table 2-2). 2.8.2 Operation Once startup is successful, configure the ROC800 to meet the requirements of the application.
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ROC800-Series Instruction Manual Chapter 3 – Power Connections This chapter discusses the Power Input modules. It describes the modules, explains how to install and wire them, and provides worksheets to help you determine—and tune—the power requirements for the I/O and communications modules you can install in the ROC800 and the EXPs. In This Chapter 3.1 3.2 3.3 3.4 3.5 3.6 3.1 Power Input Module Descriptions ........................................................................3-1 3.1.
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ROC800-Series Instruction Manual E A B C F D G H A B C D E F G H BAT+ / BAT– CHG+ / CHG– AUX+ / AUX– AUX SW + / AUX SW – V OK LED V OFF LED V OVER LED TEMP LED Figure 3-1. 12 Volt dc Power Input Module The CHG+ and CHG– terminals comprise an Analog Input channel that allows you to monitor an external voltage between 0 to 18 Volts dc. For example, you can connect a solar panel upstream of the solar regulator to monitor the output of the solar panel.
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ROC800-Series Instruction Manual Table 3-1. 12 Volt dc Power Input Terminal Block Connections Terminal Blocks BAT+ and BAT– CHG+ and CHG– AUX+ and AUX– AUX SW + and AUX SW – Definition Volts DC Accepts 12 Volts dc nominal from an AC/DC converter or other 12 Volts dc supply.  Maximum Range: 11.5 to 16 Volts dc  Recommended Operating Range: 11.5 to 14.5 Volts dc Analog Input used to monitor an external charging source. Supplies reverse polarity protected source voltage to external devices. Fused.
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ROC800-Series Instruction Manual C A D B A B C D +/– AUX+ / AUX– V 12 LED V 3.3 LED Figure 3-2. 24 Volt dc Power Input Module Table 3-3. 24 Volt dc Power Input Terminal Block Connections Terminal Blocks + and – AUX+ and AUX– Definition Volts DC Accepts 24 Volts dc nominal from an AC/DC converter or other 24 Volts dc supply. Supplies reverse polarity protected source voltage to external devices. Circuit limited. 20 to 30 Volts dc +12 Volts dc minus ∼0.7 Volts dc Table 3-4.
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ROC800-Series Instruction Manual expanded backplanes. With this module installed, the ROC800 requires 10.5 to 30 Volts dc for proper operation. Use the AUX+ and AUX– terminals to supply reverse polarity protected source voltage to external devices, such as a radio or solenoid. D A E B F C G H A B C D E F G H Power Input Voltage + / – AUX+ / AUX– AUX SW + / AUX SW – Voltage present at Power Input AUX Output enabled Switched AUX Output enabled 12v power to backplane 3.
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ROC800-Series Instruction Manual Low Voltage Cutoff The design of the PM-30 power module (like the PM-24 power module it replaces) does not include the low voltage cutoff feature present in the PM-12 power module. In the PM-12 module, when power falls below the set LoLo alarm (a default of 10.1V), the module ceases to provide power to the backplane. Thus, the module shuts down CPU operations. Remote Automation Solutions continues to offer the PM-12 for installations requiring low voltage cutoff.
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ROC800-Series Instruction Manual SOLAR PANEL LOW VOLTAGE DISCONNECT SOLAR POWER REGULATOR Figure 3-5. Low voltage disconnect device between the solar regulatory circuitry and the ROC800  Use the Auxiliary Switch (AUX SW) output terminals on the PM-30. If shutting down power to an external device is sufficient, then connecting to the Auxiliary Switch (AUX SW) terminals on the PM-30 power module ensures power is cut off when the LoLo alarm is triggered.
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ROC800-Series Instruction Manual 3.1.4 Auxiliary Output (AUX+ and AUX–) You can use the AUX+ and AUX–terminals to supply reverse polarity protected source voltage to external devices, such as a radio or a solenoid. All module terminal blocks accept 12 to 22 AWG wiring. Refer to Figures 3-3 and 3-4. PM-12 For the 12-volt dc Power Input module (PM-12), the auxiliary output follows the voltage located at BAT+ minus ~0.7 Volts dc, which is the protection diode voltage drop.
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ROC800-Series Instruction Manual Figure 3-8. Auxiliary Power Wiring for PM-24 Module PM-30 For the 30 volt dc Power Input module (PM-30), the auxiliary output follows the voltage located at BAT+ minus ~1.0 Volts dc, which is the protection diode voltage drop. For example, if the BAT+ voltage is 13 volts dc, then AUX+ is ~12.3 Volts dc. For the PM-30 Power Input module, AUX+ / AUX– is always on and is internally current-limited by a .9 Amp Positive Temperature Coefficient (PTC).
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ROC800-Series Instruction Manual Removing the Auxiliary Output Fuse To remove the auxiliary output fuse: 1. Perform the procedure described in Section 3.3, Removing a Power Input Module. 2. Remove the fuse located at F1 on the Power Input module. Installing the Auxiliary Output Fuse To re-install the auxiliary output fuse: 1. Replace the fuse located at F1 on the Power Input module. 2. Perform the procedure described in Section 3.4, Installing a Power Input Module. 3.1.
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ROC800-Series Instruction Manual detect circuit includes approximately 0.75 Volts dc of hysteresis between turn-off and turn-on levels. For further information on the STATUS LED functions, refer to Table 2-2 in Chapter 2, Installation and Use. 3.2 Determining Power Consumption Determining the power consumption requirements for a ROC800 configuration involves the following steps: 1.
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ROC800-Series Instruction Manual individual worksheets to determine how to best “tune” your configuration and lessen power demands. General Calculation Process To calculate the power requirements of a ROC800 configuration requires: 1. Determine the kind and number of communication modules and the kind and number of expanded backplanes you are implementing. Enter those values in the Quantity Used column of Table 3-5. 2. Multiply the P Typical value by the Quantity Used.
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ROC800-Series Instruction Manual depending on external influences. Adjust the factor value up or down accordingly. 10. Add the value for the Power System Safety Factor (0.25) to the value for Total for ROC800 Base Unit, All Modules, and Other Devices to determine the total estimated power consumption for the configured ROC800 system.
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ROC800-Series Instruction Manual Table 3-7. Estimated Power Consumption Power Consumption (mW) Device Description P TYPICAL Quantity Used Sub-Total (mW) CPU and ROC809 Backplane Power Input Module PM-12 (60W max) 87.5 mA @ 12 volts dc 1050 mW Power Input Module PM-24 (24W max) 102.1 mA @ 24 volts dc 2450 mW Power Input Module PM-30 (70W max) 115 mA @ 11 volts dc 1265 mW Power Input Module PM-30 (80W max) 102 mA @ 30volts dc 3060 mW 1.5 mA 18 mW Power Input Module PM-12 104.
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ROC800-Series Instruction Manual 3.2.1 Tuning the Configuration The PM-12 Power Input module can supply a maximum of 60 W (60,000 mW) to the backplane. The PM-24, when operating between –40°C to 55°C, can supply a maximum of 30 W (30000 mW) to the backplane. Across its entire operating range (–40°C to 85°C) the PM-24 can supply 24 W (24000 mW). The PM-30 Power Input module can supply a maximum of 70 W( at 11 volts dc ) (70,000 mW) to 80W(at 30 volts dc) (80,000mW) at -40°C to 75°C to the backplane.
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ROC800-Series Instruction Manual Table 3-8. Power Consumption of the Analog Input Module I/O Module Power Consumption (mW) Description Analog Input AI Module Base 84 mA @ 12 volts dc Jumper set for +T @ 12 volts dc Channel’s mA current Channel 1 draw from +T * 1.25 * 12 Channel’s mA current Channel 2 draw from +T * 1.25 * 12 Channel’s mA current Channel 3 draw from +T * 1.25 * 12 Channel’s mA current Channel 4 draw from +T * 1.
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ROC800-Series Instruction Manual Table 3-9. Power Consumption of the Analog Output Module Power Consumption (mW) I/O Module Description AO Module Base 100 mA @ 12 volts dc Jumper set for +T @ 12 volts dc Channel’s mA current Channel 1 draw from +T * 1.25 * 12 Channel’s mA current Channel 2 draw from +T * 1.25 * 12 Channel’s mA current Channel 3 draw from +T * 1.25 * 12 P TYPICAL Quantity Used Duty Cycle Sub-Total (mW) 1200 mW Channel’s mA current draw from +T * 1.
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ROC800-Series Instruction Manual Table 3-10. Power Consumption of the Discrete Input Module Power Consumption (mW) I/O Module Description 19 mA @ 12 volts dc No Channels Active 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc 3.2 mA @ 12 volts dc DI Module Base Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 Per Active LED – Maximum 8 1.
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ROC800-Series Instruction Manual Table 3-11. Power Consumption of the Discrete Output Module Power Consumption (mW) I/O Module Description 20 mA @ 12 volts dc No Channels Active 1.5 mA 1.5 mA 1.5 mA 1.5 mA 1.5 mA DO Module Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Per Active LED – Maximum 5 1.
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ROC800-Series Instruction Manual Table 3-12. Power Consumption of the Discrete Output Relay Module I/O Module Power Consumption (mW) Description DOR Module Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Per Active LED – Maximum 5 6.8 mA @ 12 volts dc No Channels Active 150 mA for 10 mSec during transition 150 mA for 10 mSec during transition 150 mA for 10 mSec during transition 150 mA for 10 mSec during transition 150 mA for 10 mSec during transition 1.
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ROC800-Series Instruction Manual Table 3-13. Power Consumption of the High and Low Speed Pulse Input Module Power Consumption (mW) I/O Module Description PI Module Channel 1 Channel 2 Per Active LED – Maximum 4 Jumper set to +T @ 12 volts dc Jumper set to +T @ 24 volts dc P TYPICAL 21 mA @ 12 volts dc No Channels Active 7.4 mA 7.4 mA 88.8 mW 88.8 mW 1.5 mA 18 mW Quantity Used Duty Cycle Sub-Total (mW) 252 mW 1.25 * Measured Current Draw at +T Terminal 2.
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ROC800-Series Instruction Manual Table 3-14. Power Consumption of the MVS Module Power Consumption (mW) I/O Module Description P TYPICAL 112 mA @ 12 volts dc 1344 mW Per Active LED – Maximum 2 1.5 mA 18 mW Power provided by the module for the MVS sensors 1.25 * Measured Current Draw at + Terminal MVS Module Quantity Used Duty Cycle Sub-Total (mW) 1 Table Total Note: For an MVS sensor, the typical mW per MVS is about 300 mW.
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ROC800-Series Instruction Manual Table 3-16. Power Consumption of the APM Module Power Consumption (mW) I/O Module APM Module Power provided by the module’s +T port Description P TYPICAL 110 mA @ 12 volts dc 1.25 * Measured Current Draw (from +T port in mA) * 24 1300 mW Quantity Used Duty Cycle Sub-Total (mW) 1 1 Table Total Table 3-17. Power Consumption of the RTD Module Power Consumption (mW) I/O Module Description RTD Module P TYPICAL 65 mA @ 13.
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ROC800-Series Instruction Manual Table 3-19. Power Consumption of the HART-2 Module Power Consumption (mW) Other Device HART-2 Module Base Each Channel Description P TYPICAL 110 mA @ 12 volts dc Channel’s mA current draw from +T * 2.50 * 12 1320 mW Quantity Used Duty Cycle Sub-Total (mW) Table Total Table 3-20.
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ROC800-Series Instruction Manual Table 3-22.
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ROC800-Series Instruction Manual A A Battery Figure 3-9. Backup Battery on Series 2 CPU Module 3.4 Installing a Power Input Module To install the Power Input module: Caution Failure to exercise proper electrostatic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations.
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ROC800-Series Instruction Manual 4. Return power to the ROC800. 5. Replace the wire channel cover. 6. Review Restarting the ROC800 in Chapter 6, Troubleshooting. 3.5 Connecting the ROC800 to Wiring The following paragraphs describe how to connect the ROC800 to power. Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment. Use 12 to 22 American Wire Gauge (AWG) wire for all power wiring.
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ROC800-Series Instruction Manual  For PM-24 (24 Volts dc source): into the clamp beneath the appropriate POWER INPUT+ and POWER INPUT– termination screws.  For PM-30 (30 Volts dc source): into the clamp beneath the appropriate POWER INPUT+ and POWER INPUT– termination screws. Figure 3-11. 12 Volts dc Power Supply and BAT+ / BAT- Wiring 6. Screw each wire into the terminal block. 7. Plug the terminal block connector back into the socket. 8.
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ROC800-Series Instruction Manual Figure 3-12. 12 Volt dc Power Supply and CHG+ / CHG– Wiring 9. Replace all other power sources (if necessary) to the ROC800. 10. Review Restarting the ROC800 in Chapter 6, Troubleshooting. Note: Refer to Table 3-2 concerning LEDs. 3.5.2 Wiring the External Batteries You can use external batteries as the main source of power for the ROC800 with the 12 volts dc Power Input module (PM-12).
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ROC800-Series Instruction Manual Battery Reserve Battery reserve is the amount of time that the batteries can provide power without discharging below 20% of their total output capacity. The battery reserve should be a minimum of five days, with ten days of reserve preferred. Add 24 hours of reserve capacity to allow for overnight discharge. Space limitations, cost, and output are all factors that determine the actual amount of battery capacity available.
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ROC800-Series Instruction Manual Type Coin Type Capacity 280 mAh minimum Acceptable Types     Duracell DL2430 Eveready CR2430 Sanyo CR2430 Varta CR2430 Note: Remove the internal backup battery if you intend to store the ROC800 for an extended period. Caution When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing these procedures.
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ROC800-Series Instruction Manual 3.6 Additional Technical Information Refer to the following technical documentation (available at www.EmersonProcess.com/Remote) for additional and most-current information. Table 3-24.
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ROC800-Series Instruction Manual Chapter 4 – Input/Output Modules This chapter describes the Input/Output (I/O) modules used with the ROC800 and expansion backplanes and contains information on installing, wiring, and removing those modules. In This Chapter 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 I/O Module Overview.............................................................................. 4-1 Installation ............................................................
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ROC800-Series Instruction Manual A DOC0513A Front View Side View A Terminal Blocks Figure 4-1. Typical I/O Module E A F G B H I C J K D A B C D E F I/O Slot #1 (Comm 3) I/O Slot #2 (Comm 4) I/O Slot #3 (Comm 5) Wire Channel Cover I/O Slot #4 I/O Slot #7 G H I J K I/O Slot #5 I/O Slot #8 I/O Slot #6 I/O Slot #9 Module Slot Cover Figure 4-2.
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ROC800-Series Instruction Manual I/O modules for the ROC800 include:  Analog Input (AI) modules that provide the ability to monitor various analog field values.  Discrete Input (DI) and Pulse Input (PI) modules that provide the ability to monitor various discrete and pulse input field values.  Analog Output (AO), Discrete Output (DO), and Discrete Output Relay (DOR) modules that provide the ability to manage various control devices.
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ROC800-Series Instruction Manual 4.2 Installation Caution Failure to exercise proper electrostatic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations. When installing units in a hazardous area, make sure all installation components selected are labeled for use in such areas. Installation and maintenance must be performed only when the area is known to be nonhazardous.
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ROC800-Series Instruction Manual Note: The tabs on the top side of the wire channel cover should rest in the slots on the top edge of the channel. 4.2.2 Removing and Installing Module Slot Covers Before you insert an I/O or communications module, remove the module cover (see Figure 4-2) over the empty module slots in which you intend to install the modules.
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ROC800-Series Instruction Manual  If the slot is currently empty, remove the module cover. 3. Insert the new I/O module through the module slot on the front of the ROC800 or EXP housing. Make sure the label on the front of the module faces right side up (refer to Figure 4-3). Gently slide the module in place until it contacts properly with the connectors on the backplane. Note: If the module stops and will not go any further, do not force the module. Remove the module and see if the pins are bent.
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ROC800-Series Instruction Manual 4.2.4 Removing an I/O Module To remove an I/O module: 1. Remove the wire channel cover. 2. Disconnect the field wiring. 3. Unscrew the two captive screws holding the module in place. 4. Gently pull the module’s lip out and remove the module from the slot. You may need to gently wiggle the module. 5. Install a new module or install the module cover. 6. Screw the two captive screws to hold the module or cover in place. 7. Replace the wire channel cover. 4.2.
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ROC800-Series Instruction Manual D301250X012) or the ROCLINK 800 Configuration Software User Manual (for ROC800L) (Part Number D301246X012). Note: The AI-16 module provides 16-bit resolution and uses a 24-bit A/D converter. DIP switches on the AI-16 module (see Figure 46) allow you to select between current and voltage loop input. You can configure the AI (+T) module as either 12 or 24 Volt dc using jumper J4 on the AI-12 module (see Figure 4-4).
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ROC800-Series Instruction Manual On the AI-16 module, you use jumper J3 to configure the AI (+T) as 12 or 24 Volts dc. Additionally, two DIP switches on the module allow you to select between current and voltage loop input. A A I indicates current loop input; V indicates voltage loop input Figure 4-6. AI-16 DIP Switches Caution 4.4 You can induce ground loops by tying commons from various modules together.
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ROC800-Series Instruction Manual A A 12V / 24V dc Jumper Figure 4-7. Analog Output Jumper J4 (Shown Set to +12V) Representative Internal Circuit Field Wiring CURRENT LOOP CONTROL + - I CURRENT LOOP CONTROL CURRENT LOOP DEVICE 4-20mA ROC800 POWERED CURRENT LOOP CONTROL +V CURRENT LOOP CONTROL 250 + - 1-5 VOLT CONTROL DEVICE DOC0505A Figure 4-8. Analog Output Module Field Wiring Caution 4.5 You can induce ground loops by tying commons from various modules together.
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ROC800-Series Instruction Manual The DI module provides a source voltage for dry relay contacts or for an open-collector solid-state switch. The DI module’s LEDs light when each input is active. Each DI channel can be software-configured to function as a momentary or latched DI (see the ROCLINK 800 Configuration Software User Manual (for ROC800-Series), Part Number D301250X012 or the ROCLINK 800 Configuration Software User Manual (for ROC800L), Part Number D301246X012).
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ROC800-Series Instruction Manual 4.6 Pulse Input (PI) Modules The Pulse Input (PI) module provides two channels for measuring either a low speed or high speed pulse signal. The PI module processes signals from pulse-generating devices and provides a calculated rate or an accumulated total over a configured period. Supported functions are slow-counter input, slow rate input, fast counter input, and fast rate input.
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ROC800-Series Instruction Manual Representative Internal Circuit Field Wiring 12KHz PI FILTER & LEVEL DETECTION 125KHz PI FILTER & LEVEL DETECTION + - OPEN DRAIN TYPE OR OPEN COLLECTOR DEVICE EXTERNALLY POWERED + - CONTACT-CLOSURE DEVICE EXTERNALLY POWERED DOC0510B Figure 4-11.
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ROC800-Series Instruction Manual configured to either retain the last value on reset or use a user-specified fail-safe value. The DO module provides LEDs that light when each output is active. When a request is made to change the state of a DO, the request is immediately sent to the DO module. There is no scan time associated with a DO. Under normal operating conditions, the DO channel registers the change within 2 milliseconds.
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ROC800-Series Instruction Manual Virtual DO 4.8 ROCLINK 800 provides a “virtual DO” software setting to support fieldbus devices, which may require the toggle characteristics of DO. For further information, see the ROCLINK 800 Configuration Software User Manual (for ROC800-Series) (Part number D301250X012) or the ROCLINK 800 Configuration Software User Manual (for ROC800L) (Part Number D301246X012).
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ROC800-Series Instruction Manual DO RELAY R CONTROL CH 3 LATCHING RELAY NOTE: S = SET R = RESET CH 2 S CH 1 Vs S R CH 5 CONTROL CH 4 Vs + + - - DISCRETE DEVICE SELF- POWERED + + + DISCRETE DEVICE - EXTERNALLY POWERED + - - - + - 5 CHAN DOC0509A Figure 4-14. Discrete Output Relay Module Field Wiring 4.9 Resistance Temperature Detector (RTD) Input Modules The Resistance Temperature Detector (RTD) module monitors the temperature signal from an RTD source.
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ROC800-Series Instruction Manual the RTD module. See Table 4-1, Table 4-2, and Figure 4-15. The ROC800 provides terminations for a four-wire 100-ohm platinum RTD with a DIN 43760 curve. The RTD module supports RTDs with alphas equal to 0.00385 or 0.00392 Ω/Ω/°C. You can use a two-wire or three-wire RTD probe instead of a four-wire probe, but they may produce measurement errors due to signal loss on the wiring.
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ROC800-Series Instruction Manual Table 4-2. RTD Wiring Terminal REF + – RET 4-Wire RTD Red Red White White 3-Wire RTD Jumper to + Red, Jumper to REF White White 2-Wire RTD Jumper to + Red, Jumper to REF White, Jumper to RET Jumper to – Note: The wire colors for the RTD being used may differ. Caution You can induce ground loops by tying commons from various modules together. 4.
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ROC800-Series Instruction Manual PI PI + +T GENERIC DENSITOMETER + + Figure 4-18. Generic Densitometer Wiring on APM ROC800 POWERED DRY CONTACT EXTERNALLY POWERED DEVICE OPEN COLLECTOR OR OPEN DRAIN TYPE Figure 4-19. Input Detector Wiring on APM DET SW 1 DET SW 1 DET SW 2 DET SW 2 Figure 4-20. Series Detector Switch (Normally Open) Wiring on APM Figure 4-21.
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ROC800-Series Instruction Manual +12 10K NO CONNECTION EXTERNAL DEVICE CONTROL Figure 4-24. Pulse Output Wiring on APM DIP Switch Settings The APM card’s daughterboard contains several DIP switches which you use to control the module’s activities. See Figure 4-25 for the switch locations and labels; see Table 4-3 for the settings. S4 S2 S1 S3 S5 Figure 4-25. DIP Switches on APM Table 4-3.
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ROC800-Series Instruction Manual Switch Channel 3 2 S3 4 Detector 2 S4 Detector 1 4 S5 N/A 1 Side Function Switch Position Right No Pullup Resistor Down Left 10 kΩ Pullup to 12 V dc Up Left No Pullup Resistor Down Right 10 kΩ Pullup to 12 V dc Up Right No Pullup Resistor Down Left 10 kΩ Pullup to 12 V dc Up Left No Pullup Resistor Down Right 10 kΩ Pullup to 12 V dc Up Right No Pullup Resistor Down Left Pulse Output Up Left Pulse Input Down Right N/A N/A 1 1 D
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ROC800-Series Instruction Manual The MVS I/O module consists of interface electronics that provide the communications link between the ROC800 and the MVS devices. The interface electronics controls communications with the sensor module, provides scaling of process variables, aids calibration, stores operating parameters, performs protocol conversion, and responds to requests from the ROC800. The ROC800 supports up to two MVS I/O modules.
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ROC800-Series Instruction Manual Figure 4-29 shows the field wiring diagram for the MVSI/O module. Figure 4-28. MVS Field Wiring Figure 4-29. MVS I/O Field Wiring Note: A “star” configuration for transmitters may not be reliable. Terminations are recommended for long distances (greater that 1000 meters) at the extreme ends of the circuit. Terminate the two outermost devices to reduce signal reflection in the circuit. The MVS termination jumper is located at J4 on the module.
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ROC800-Series Instruction Manual Figure 4-30. MVS Jumper J4 (Shown Not Terminated) Four wires run from the MVS module terminal block and connect to the sensor. The wires should be a minimum size of 22 AWG and a maximum length of 1220 m (4000 ft). Note: Insulated, shielded, twisted-pair wiring is required when using MVS signal lines. Two of the terminal blocks provide power and the other two terminals provide a communication path. Table 4-5 identifies the terminals. Table 4-4.
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ROC800-Series Instruction Manual 4.12 Alternating Current Input/Output (AC I/O) Module EMC issues restrict the use of the AC I/O module only to devices using Warning a PM-12 power module. You cannot use the AC I/O module in a device that uses either a PM-24 or PM-30 power module. Switchable I/O and LEDs The module has one bank of six DIP switches on its daughterboard (see Figure 4-31), which controls the input/output status of each of the six channels.
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ROC800-Series Instruction Manual EXTERNAL AC PWR/PERMISSIVE SOURCE Vs CONTROL SOLID-STATE RELAY AC CONTROLLED DEVICE Vs CONTROL SOLID-STATE RELAY AC CONTROLLED DEVICE Figure 4-32. AC I/O Module (Output Field Wiring) Note: If the label on your AC I/O module does not indicate 120/240V, your module is designed for use only with 120V. Additionally, all AC wiring must be shielded. AC Discrete Inputs You can configure each channel as an AC input/detector.
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ROC800-Series Instruction Manual Note: If the label on your AC I/O module does not indicate 120/240V, your module is designed for use only with 120V. Additionally, all AC wiring must be shielded. Table 4-5.
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ROC800-Series Instruction Manual Compensation (CJC) correction factor is applied to compensate for errors due to any voltage inducted at the wiring terminals by the junction between the different metal of the TC wiring and the TC module’s terminal blocks. Note: The use of dissimilar metals is not supported. It does not provide the correct results, as CJC is applied at the module level. Thermocouples are self-powered and require no excitation current.
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ROC800-Series Instruction Manual Figure 4-34. Thermocouple Input Module Wiring Be sure to use the correct type of thermocouple wire to connect the thermocouple to the ROC800. Minimize connections and make sure connections are tight. If you use any dissimilar metals (such as copper wire) to connect a thermocouple to the ROC800, you can create the junction of dissimilar metals that can generate millivolt signals and increase reading errors.
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ROC800-Series Instruction Manual so minimize noise where possible. Take care to properly shield thermocouple wiring from noise by separating the thermocouple wiring runs from signals that are switching loads and AC signals. Route wires away from noisy areas and twist the two insulated leads of the thermocouple cable together to help ensure both wires pick up the same noise. When operating in an extremely noisy environment, use a shielded extension cable. Shielded wiring is highly recommended.
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ROC800-Series Instruction Manual 4.14 Highway Addressable Remote Transducer (HART®) Module Note: The HART-2 module (labeled HART-2 with black faceplate) replaces the HART module (with gray faceplate). The HART-2 module allows a ROC800 to communicate with HART devices using the HART protocol. The HART-2 module receives signals from and transmit signals to HART devices. LEDs provide a visual indication of the status of each HART channel. Refer to Figure 438.
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ROC800-Series Instruction Manual commands conform to HART Universal Command Specification Revision 5.1 and Common Practice Command Specification Revision 7, (HCF SPEC 127 and 151). Refer to www.hartcomm.org for more information on the specifications. The HART-2 module polls the channels simultaneously. If more than one device is connected to a channel in a multi-drop configuration, the module polls one device per channel at a time.
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ROC800-Series Instruction Manual Figure 4-38. Input Point-to-Point Wiring on HART-2 Module Figure 4-39. Input Multi-Drop Wiring on HART2 Module Figure 4-40. Output Wiring on HART-2 Module 4.15 IEC 62591 Module The IEC 62591 Interface module allows a ROC800-Series Remote Operations Controller (ROC800) to communicate with any mix of up to 60 WirelessHART™ field devices.
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ROC800-Series Instruction Manual The IEC 62591 Interface consists of two parts: the Smart Wireless Field Link that provides the radio link to the WirelessHART field devices, and the IEC 62591 Interface Module that installs into the ROC800. Installation and Configuration The IEC 62591 Interface module connects to the Smart Wireless Field Link through a four-wire connection.
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ROC800-Series Instruction Manual 4.16 APP 485 Module The Application module (APP 485) provides a solution to add user applications to the ROC800-Series (ROC800) by simply installing a module. The APP 485 module streamlines the installation process by including all point types and screens associated with the application, and the module is automatically recognized by ROC800 firmware.
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ROC800-Series Instruction Manual 4.17 Additional Technical Information Refer to the following technical documentation (available at www.EmersonProcess.com/Remote) for additional and most-current information on each of the I/O modules. Table 4-6.
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ROC800-Series Instruction Manual Chapter 5 – Communications This chapter describes the built-in communication ports and the optional communication modules used with the ROC800. In This Chapter 5.1 5.2 5.3 5.4 5.5 Communication Ports and Modules Overview ....................................... 5-1 Installing Communication Modules ........................................................ 5-3 Removing a Communication Module .....................................................
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ROC800-Series Instruction Manual the backplane. The ROC800 can hold up to three communication modules in the first three module slots. Refer to Figure 5-1. D E A B F C A B C D E F LOI (Local Port) EIA-232 (RS-232D) Built-in Ethernet (Comm1) Built-in EIA-232 (RS-232) (Comm2) Optional Comm 3 (Slot #1) Optional Comm 3 or Comm 4 (Slot #2) Optional Comm 3 to Comm 5 (Slot #3) Figure 5-1. Communication Ports Table 5-2.
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ROC800-Series Instruction Manual field interface has been designed to protect the electronics in the module. Filtering is provided on each module to reduce communication errors. 5.2 Installing Communication Modules All communication modules install into the ROC800 in the same way. Caution The design of ROC800-Series communication and I/O modules supports “hot-swapping” (replacing similar modules in the same slot) and “hotplugging” (inserting modules into an empty slot) while the ROC800 is powered.
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ROC800-Series Instruction Manual Note: With the exception of the HART module, you can install communication modules only in slots 1, 2, or 3 of the ROC800. Refer to Figure 5-1 and Table 5-1. 1. Remove the wire channel cover. Note: Leaving the wire channel cover in place can prevent the module from correctly connecting to the socket on the backplane. 2.
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ROC800-Series Instruction Manual 5.3 Removing a Communication Module To remove a communication module: 1. Remove the wire channel cover. 2. Unscrew the two captive screws holding the module in place. 3. Gently pull the module’s lip out and remove the module from the slot. You may need to gently wiggle the module. 4. Install a new module or install the module cover. 5. Screw the two captive screws to hold the module cover in place. 6. Replace the wire channel cover. 5.
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ROC800-Series Instruction Manual direct connection using ROCLINK 800 software to configure and transfer stored data. The LOI uses the Local Port in ROCLINK 800 software. The LOI terminal (RJ-45) on the CPU provides wiring access to a builtin EIA-232 (RS-232) serial interface, which is capable of 57.6K baud operation. The RJ-45 connector pin uses the data terminal equipment (DTE) in the IEEE standard. The LOI port supports ROC Plus and Modbus protocol communication.
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ROC800-Series Instruction Manual EIA-232 (RS-232) DTE 2 7 8 Adaptor Cable ROC800Series RX – RTS RJ-45 Pins on ROC800Series 6 7 8 Remote Automation Solutions offers an adaptor cable to resolve this cabling issue. Order CBL8A from your Remote Automation Solutions salesperson. 5.5.1 Using the LOI 1. Plug the LOI cable into the LOI RJ-45 connector of the ROC800. 2. Connect the LOI cable to the D-Sub 9 pin (F) to RJ-45 modular converter. 3. Plug the modular converter into the COM port of the PC. 4.
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ROC800-Series Instruction Manual mechanism is based on Carrier Sense Multiple Access with Collision Detection (CSMA/CD). If two stations begin to transmit a packet at the same instant, the stations stop transmitting (Collision Detection). Transmission is rescheduled at a random time interval to avoid the collision. You can link Ethernet networks together to form extended networks using bridges and routers. Table 5-5.
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ROC800-Series Instruction Manual designed so that you do not need to be concerned about cable crosstalk, provided the cable meets all other requirements. Noise can be caused by crosstalk of externally induced impulses. Impulse noise may cause data errors if the impulses occur at very specific times during data transmission. Generally, do not be concerned about noise. If you suspect noise related data errors, it may be necessary to either reroute the cable or eliminate the source of the impulse noise.
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ROC800-Series Instruction Manual  Built-in – Comm2 EIA-232 (RS-232C).  Module – Comm3 to Comm5 EIA-232 (RS-232C). EIA-232 (RS-232) uses point-to-point asynchronous serial communication and is commonly used to provide the physical interface for connecting serial devices, such as gas chromatographs and radios to the ROC800-Series. EIA-232 (RS-232) communication provides essential hand-shaking lines required for radio communication, such as DTR and RTS.
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ROC800-Series Instruction Manual used to multi-drop units on a serial network over long distances using inexpensive twisted-pair wiring. EIA-422 (RS-422) drivers are designed for party-line applications where one driver is connected to, and transmits on, a bus with up to ten receivers. EIA-422 (RS-422) allows long distance point-to-point communication and the drivers are designed for true multi-point applications with up to 32 drivers and 32 receivers on a single bus.
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ROC800-Series Instruction Manual Terminations are required on the two EIA-422/485 (RS-422/485) communication modules located at the extremities of the circuit. That is to say, the two outside modules require terminations in order to complete the communication circuit. Figure 5-5. EIA-422/485 (RS-422/485) Jumpers Table 5-10. EIA-422 (RS-422) Module Terminated Not Terminated Jumper TER J3 J4 J5 J6 Out Half Full x TER x Out Half Full x x x x x x Table 5-11.
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ROC800-Series Instruction Manual 5.9 Dial-up Modem Communication Module The dial-up modem module interfaces to a Public-Switched Telephone Network (PSTN) line, and requires a telephone line connection. The module provides a telephone interface on the host port that is capable of both answering and originating telephone calls. The module also provides electronics that conserve power when the phone line is not in use. Note: When installing a dial-up modem module, you must remove power from the ROC800.
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ROC800-Series Instruction Manual Notes:  If you are installing a modem module, it is recommended that you install a surge protector between the RJ-11 jack and the outside line.  The dial-up modem is not hot-swappable or hot-pluggable. When installing a dial-up modem module, you must remove power from the ROC800. 5.
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ROC800-Series Instruction Manual The NRM provides a wireless solution of transferring data from RTU to another RTU within the Distributed RTU Network (DRN). The data can be any type of information that the RTU has in its database, such as I/O, soft points, or other information. The NRM includes a FreeWave radio to handle the wireless data transmission.
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ROC800-Series Instruction Manual 5.12 Additional Technical Information Refer to the following technical documentation (available at www.EmersonProcess.com/Remote) for additional and most-current information. Table 5-14.
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ROC800-Series Instruction Manual Chapter 6 – Troubleshooting This chapter provides generalized guidelines for troubleshooting the ROC800-Series. Perform the procedures in this chapter before you remove power from the ROC800 for any reason, after you restore power to the ROC800, and if you disassemble the ROC800. Use the following tools for troubleshooting:  Personal computer running a Microsoft® Windows® XP (Service Pack 3), Windows Vista (32-bit), or Windows 7 (32-bit) operating system.
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ROC800-Series Instruction Manual When you are done troubleshooting, perform the restart procedure as described in Restarting the ROC800 in this chapter. 6.2 Checklists If the LEDs do not display:  By default, LEDs on the communication modules and I/O modules enter Sleep mode after five minutes.  To turn the LEDs on, press the LED button located on the CPU for one second. Note: Using the ROCKLINK 800 software, you can disable this feature so that the LEDs always remain on. 6.2.
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ROC800-Series Instruction Manual 6.2.2 I/O Point If you are experiencing troubles with an I/O point (Analog Input, Analog Output, Discrete Input, Discrete Output, Pulse Input, RTD Input, or Thermocouple Input):  Check (using ROCLINK 800 software) to see how the channel is configured.  If the configuration looks correct, then follow the procedure for troubleshooting that type of I/O (refer to Chapter 6).
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ROC800-Series Instruction Manual Restore to To restore the ROC800 to factory defaults (that is, as the ROC800 Factory Defaults was delivered to you from the factory without installed user programs, FLASH memory contents, FSTs, DS800 applications, or configurations) without connecting to ROCLINK 800, use this procedure: 1. Remove power from the ROC800. 2. Press and hold the RESET button on the CPU. Note: Use a small screwdriver or a straightened paper clip to press the RESET button. 3.
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ROC800-Series Instruction Manual 6.2.6 IEC 62591 Module If you are experiencing trouble with the IEC 62591 module:  6.3 If the IEC 62591module is already set up, a power cycle of the devices will speed up the discovery of other devices. Procedures Use the following procedures to resolve various issues with the I/O modules. 6.3.
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ROC800-Series Instruction Manual Caution Ensure all input devices, output devices, and processes remain in a safe state upon restoring power. An unsafe state could result in property damage. When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing procedures. Performing these procedures in a hazardous area could result in personal injury or property damage.
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ROC800-Series Instruction Manual Caution Failure to exercise proper electrostatic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations. 1. Connect a multimeter across the scaling resistor connected to the + and COM terminals of the module and set the multimeter to measure voltage. 2. Connect to ROCLINK 800 software. 3. Select Configure > I/O > AI Points. The Analog Input screen displays. 4.
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ROC800-Series Instruction Manual 9. Remove the test equipment. 6.3.4 Troubleshooting Analog Output Modules Equipment Required: Caution  Multimeter.  PC running ROCLINK 800 software. Failure to exercise proper electrostatic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations. To calibrate the module: 1.
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ROC800-Series Instruction Manual 14. Select the General tab on the Analog Output screen. 15. Remove the test equipment, and reconnect the field device. 16. If possible, verify the correct operation of the AO module by setting the values in the High Reading EU and Low Reading EU fields to the values you recorded in step 9 and observing the field device. 6.3.
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ROC800-Series Instruction Manual 3. Remove all wiring from the DO module. 4. Connect the multimeter set up to measure ohms to the channel that you are testing. 5. Measure the resistance with the DO Status OFF. It should be over 2 megohms. 6. Measure the resistance with the DO Status ON. It should be approximately 1 ohm. 6.3.
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ROC800-Series Instruction Manual 3. Select Configure > I/O > PI Points. The Pulse Input screen displays. 4. Select the correct Pulse Input Point number. 5. Connect a pulse generator having sufficient output to drive the module to terminals L+ or H+ and COM. The pulse generator must synthesize a square wave signal of 50% for every cycle. 6. Connect a frequency counter across terminals L+ or H+ and COM. 7. Set the pulse generator to a value equal to or less than (<=) 10 KHz. 8.
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ROC800-Series Instruction Manual 7. Select Configure > I/O > RTD Points. The RTD Input screen displays. 8. Disconnect the RTD and connect one jumper between the – terminal and RET and another jumper between the + terminal and the REF of the RTD module. 9. Connect either an accurate resistor or decade resistance box with a value to give a low end reading across the + and – terminals.
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ROC800-Series Instruction Manual Caution Failure to exercise proper electrostatic discharge precautions, such as wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations. To test the thermocouple module: 1. Disconnect the thermocouple from the thermocouple module. 2. Generate the correct J or K signal using a multimeter and connect the wiring from the multimeter to the T/C module. 3.
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ROC800-Series Instruction Manual 8. Finally, connect a thermocouple of the same type directly to the ROC800. If it reads correctly, the problem is likely to be in the wiring to the field or may be related to a ground loop. 6.3.
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ROC800-Series Instruction Manual 3. Verify that Access Points have unique settings for the Network ID and Channel.  If a duplicate Network ID and Channel exists on the network, a node may indicate connectivity to a Network but will not appear in the Discovery list.  A node will not appear on the Access Points Discovery list if there is a second unit setup as an access point. 4.
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ROC800-Series Instruction Manual Chapter 7 – Calibration This chapter provides overview information about calibration procedures for the Analog Input (AI) modules, HART module, RTD Input module, and Multi-Variable Sensor modules (MVS and MVS I/O). For the full calibration procedure, refer Refer to the ROCLINK 800 Configuration Software User Manual (for ROC800-Series) (Part Number D301250X012)or the ROCLINK 800 Configuration Software User Manual (for ROC800L) (Part Number D301246X012). In This Chapter 7.
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ROC800-Series Instruction Manual organization is in compliance with appropriate industry and governmental requirements. 7.3 Preparing for Calibration Before calibrating the inputs from a sensor, HART device, or other device, you should prepare the ROC800. 1. Verify the inputs are correctly wired. For information on wiring the inputs, refer to Chapter 4, Input/Output Modules. 2.
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ROC800-Series Instruction Manual Appendix A – Glossary Note: This is a generalized glossary of terms. Not all the terms may necessarily correspond to the particular device or software described in this manual. For that reason, the term “ROC” is used to identify all varieties of Remote Operations Controllers (including ROC800-Series, ROC800L, DL8000, FloBoss™ 107, and FloBoss™ 100-Series). Refer to Measurement Units, Symbols, and Abbreviations (Form A6302) for additional information.
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ROC800-Series Instruction Manual C (continued) COMM Communications port on a ROC used for host communications. . Note: On FloBoss 500-Series and FloBoss 407s, COMM1 is built-in for RS-232 serial communications. Comm Module Module that plugs into a ROC to provide a channel for communications via a specified communications protocol, such as EIA-422 (RS-422) or HART. CF Compare Flag; stores the Signal Value Discrete (SVD).
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ROC800-Series Instruction Manual D (continued) DRTU A primary component of the Distributed RTU Network, consisting of a FB107 chassis housing a focused functionality CPU and a Network Radio module (NRM). The DRTU collects process variables from one or more wellheads and transmits the signals throughout the designed network. DSR Data Set Ready modem communications signal. DTE Data Terminal Equipment. DTR Data Terminal Ready modem communications signal.
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ROC800-Series Instruction Manual F (continued) FSK Frequency Shift Keypad. FST Function Sequence Table, a type of user-written program in a high-level language designed by Emerson Process Management’s Flow Computer Division. Ft Foot or feet. GFA Ground Fault Analysis. GHz Gigahertz, 10 cycles per second GND Electrical ground, such as used by the ROC’s power supply. GP Gauge Pressure. H1 A Foundation Fieldbus protocol operating at 31.
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ROC800-Series Instruction Manual K KB Kilobytes. kHz KiloHertz. LCD Liquid Crystal Display. LDP Local Display Panel, a display-only device that plugs into ROC300-Series units (via a parallel interface cable) used to access information stored in the ROC. LED Light-Emitting Diode.
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ROC800-Series Instruction Manual N (continued) Node A basic structural component of the Distributed RTU Network. A node (usually a FB107 chassis housing a focused-functionality CPU and a Network Radio module) provides a data collection point that wirelessly transmits data throughout the designed network. NRM Network Radio module; a module used in both the FloBoss 107 and ROC00-Series based devices to wirelessly transmit information throughout the distributed RTU network.
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ROC800-Series Instruction Manual type of duplex. PSTN Public Switched Telephone Network. PT Process Temperature. PTT Push-to-Talk signal. Pulse Transient variation of a signal whose value is normally constant. Pulse Interface module A module that provides line pressure, auxiliary pressure, and pulse counts to a ROC. PV Process Variable or Process Value. Rack A row of slots on a ROC into which I/O modules can be plugged.
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ROC800-Series Instruction Manual S (continued) Script An uncompiled text file (such as keystrokes for a macro) that a program interprets in order to perform certain functions. Typically, the end user can easily create or edit scripts to customize the software. Soft Points A type of ROC point with generic parameters that can be configured to hold data as desired by the user. SP Setpoint, or Static Pressure. SPI Slow Pulse Input. SPK Speaker. SRAM Static Random Access Memory.
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ROC800-Series Instruction Manual Appendix B – Wiring Diagrams This appendix presents wiring examples for several standard Emerson devices. For other devices, refer to the manufacturer’s specifications. B.
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ROC800-Series Instruction Manual B.2 Daniel 1818A and 1838 Turbine Pre-Amp to PI Module DANIEL PREAMP 1818A 12KHz PI FILTER & LEVEL DETECTION 15-28 VDC B SQR. WAVE A COMMON C PICKUP COIL D E 12KHz PI FILTER & LEVEL DETECTION PICKUP COIL 15-28 VDC B SQR.
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ROC800-Series Instruction Manual B.
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ROC800-Series Instruction Manual B.7 Daniel 1818A and 1838 Dual Turbine Pre-Amp to APM Module DANIEL PREAMP 1818A 15-28 VDC B SQR. WAVE A COMMON C PICKUP COIL D E PICKUP COIL 15-28 VDC B SQR.
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ROC800-Series Instruction Manual B.8 Daniel 1818A and 1838 Turbine Pre-Amp to APM Module DANIEL PREAMP 1818A 15-28 VDC B SQR. WAVE A COMMON C 15-28 VDC B SQR.
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ROC800-Series Instruction Manual B.9 Two-Stage Valve with Two Limit Switches to ACIO Module PERMISSIVE POWER AC L1 PERMISSIVE NEUTRAL N.O. MICRO SWITCH N.C. MICRO SWITCH UPSTR SOL DNSTR SOL UPSTREAM SOLENOID N.O. DOWNSTREAM SOLENOID N.C.
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ROC800-Series Instruction Manual Index AUX Terminal ...................................................... 3-2 AUX+ and AUX– ................................... 3-2, 3-3, 3-8 LEDs ............................................................... 3-3 Auxiliary Wiring.............................................................. 3-8 Auxiliary Output ................................................... 3-8 Auxiliary Output Fuse Installing........................................................
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ROC800-Series Instruction Manual HART Interface module ................................ 4-31 Port Locations .................................................5-1 Configuration Data Preserving .......................................................6-5 Configuration, Tuning ....................................... 3-15 CPU .................................................................. 2-19 Connector Locations .................................... 2-15 Description .............................................
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ROC800-Series Instruction Manual 2-10. License Key Installation ...................... 2-19 3-1. 12 V dc Power Input module ................... 3-2 3-2. 24 Vdc Power Input module .................... 3-4 3-3. PM-30 module ......................................... 3-5 3-4. Low voltage disconnect device between ROC800 and power source .......................... 3-6 3-5. Low voltage disconnect device between solar regulatory circuitry and ROC800 ......... 3-7 3-6.
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ROC800-Series Instruction Manual Discrete Outputs ........................................... 4-13 HART2 .......................................................... 4-31 IEC 62591 .................................................... 4-33 Installation and Setup ......................................4-4 Installing ..........................................................4-5 Pulse Inputs .................................................. 4-12 Removing ........................................................
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ROC800-Series Instruction Manual Standby Mode .............................................. 1-18 Wiring ........................................................... 3-27 Power Input module ............................................ 3-1 12 Vdc ............................................................ 3-1 24 Vdc ............................................................ 3-3 30 Vdc ............................................................ 3-4 Installing ...............................................
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ROC800-Series Instruction Manual 3-24. Technical Specifications (Power Input Modules)..................................................... 3-32 4-1. RTD Signal Routing .............................. 4-17 4-2. RTD Wiring ............................................ 4-18 4-3. APM DIP Switch Settings ...................... 4-20 4-4. MVS Termination .................................. 4-23 4-5. MVS Signal Routing .............................. 4-24 4-6. Field Wiring Terminals .......................... 4-27 4-7.
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ROC800-Series Instruction Manual Revised Jul-14 Index I-7
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