CASS_Attachment_1_Description,_Operation_and_Maintenance.pdf

Section 1

Description, Operation & Maintenance

Table of Contents

1. Description Station 0 pg 3-14

2. Description Station 42 (typical Stations 42-45) pg 15-28

3. Maintenance: Control System pg 29-46

Description:

Control Station

Maintenance

1. The purpose of the Touch Screen pg 3

2. Station 0 Control Section pg 3- 5

a. AIR Control pg 3

b. Generator Control pg 4- 5

3. Locking out Air pg 6

4. Unlocking Air pg 6

5. Locking out 400Hz pg 7

6. Unlocking out 400Hz pg 7

7. Locking out Individual Stations pg 8

8. Unlocking out Individual Stations pg 8

9. Station Displays pg 9-10

a. Inactive pg 9

b. Active pg 9

c. Air pg. 9

i. Active pg 9

ii. Waiting pg 9

iii. Locked Out pg 9

iv. Manual Override pg 9

d. 400Hz pg 10

i. Active pg 10

ii. Waiting pg 10

iii. Locked Out pg 10

10. Station Emergency Stop Display pg 11

11. Station Power Off Display pg 11

12. Station Com Loss Display pg 12

13. Time & Date Adjustment pg 13

14. Backlight Level Control pg 13

1. The purpose of the Touch Screen is to provide:

a. A Overall View of the Status of each individual C.A.S.S Station

b. The Ability to Control the Maximum Number of Stations to Run at any time

c. The Ability to Lockout any station as follows:

i. Air

ii. 400 Hz Power

iii. The Entire Station

2. Station 0 Control Section:

Stations 21-41

Stations 42-45

a. Air Control: Provides the ability to limit the Maximum Number of station allowed to receive air at time.

i. Touching icons, will increase or decrease the “Max Stations”. The maximum number of Station allowed is limited to “10”.

ii. The Maximum number of allowed stations will be displayed in the “MAX” display

iii. The number of active and stations requesting air will be displayed in the “ACTIVE” display

b. Generator Control: Control the Generator as to:

i. Mode of Operation: Auto or Manual control of the Generator is selected by touching either the or icon. This will display the select icon.

1. Touching the icon, will put the Generator under Manual control

a. The display will change to

i. Touching the

1. Will Start the Generator

2. The display will change to

b. Touching the

i. will Stop the Generator

ii. The display will change to

2. Touching the icon, will put the Generator under Auto (System) control

a. The display will change to

b. When a Station requests 400 Hz power the display will change to

c. When the last Station requesting 400 Hz power is shut off. The Generator will run for the run time selected in Section 2 B ii, then shut off. The display will change to

3. Touching the icon, will cancel the selection process and the system will return to its last state

ii. Selecting the Generator Run Time: Controlled from the Touch Screen Control Section under the Generator Section

1. Touching icons will increase or decrease the “Generator Run Time”.

The maximum allowed “Run Time” is “15” minutes.

2. The time the Generator will run after there is no requests for 400 Hz power will be displayed in the “Run” display

3. The Run time till the Generator shuts Off, will be displayed in the “Till Off” display

3. Locking out Air at a Station: Controlled from the Touch Screen Touching the icon “Locks Out” the Air at the station

a. The display will change to

b. The icon changes to

4. Unlocking the Air at a Station: Controlled from the Touch Screen Touching the icon “Unlocks” the Air at the station

a. The display will change to

b. The icon changes to

5. Locking out the 400 Hz at a Station: Controlled from the Touch Screen

Touching the icon “Locks Out” the 400 Hz at the station

a. The display will change to

b. The icon changes to

6. Unlocking the 400 Hz at a Station: Controlled from the Touch Screen

Touching the icon “Unlocks” the 400 Hz at the station

a. The display will change to

b. The icon changes to

7. Locking Out Individual Stations: Controlled from the Touch Screen

Touching the icon “Locks Out” the Station

a. The display changes to

b. The icons change to

8. Unlocking Individual Stations: Controlled from the Touch Screen by touching the icon. Pressing this icon “Unlocks” the Station

a. The display changes to

b. The icons change to

9. Station Activity Displays: Displayed from the Touch Screen

a. When Stations are Inactive:

b. When Stations are Active:

c. Station Air (Typical for all Stations)

i. “Activated

ii. “Waiting”

iii. “Locked Out”

iv. “Air Manual Override”

d. Station 400Hz (Typical for all Stations)

i. “Activated

ii. “Waiting

iii. “Locked Out

10. “Station Emergency Stop”: When the “E-STOP” has been activated at a Station it will be indicated on the Touch Screen by

a. The “ESTOP” icon

b. The display will change to

c. When E-STOP has been cleared at the Station, the display will change to

11. “Station Power Off”: When the Power is “OFF” at a Station it will be indicated on the Touch

Screen by

a. The “Power Off” icon

b. The display will change to

c. When Power restored at the Station, the display will change to

12. “Station Com Loss”: When there is a “Communication Loss” between Station 0 and a Station it will be indicated on the Touch Screen by

a. The “Com Loss” icon

b. The display will change to

c. When communications are re-established between the Station and Station 0, the display will change to

13. ” Time & Date” Adjustment: The time or date can be adjusted by touching the

(time) or (date) icons. The Time adjustment (typical for Date) is made by touching the icon.

a. This will display the keypad icon

b. The icon will change to

c. Type in the new time

d. Press to enter the new time

e. The keypad will disappear

f. The icon will change to

14. “BACK LIGHT LEVEL” control: Controlled by the icon.

This icon controls the Back Light level of the display. The level may be increased or decreased to improve the visibility of the display, by touching the slider in the BACK LIGHT LEVEL icon

Control Station 22

Typical Stations 42-45

1. The purpose of the Station Screen pg 3

2. Communication Loss pg 3

3. Manual Override pg 4

4. Station Locked Out pg 4

5. Station Emergency Stopped pg 5

6. Air Request pg 6- 8

a. Sufficient Air pg 6

b. Insufficient Air pg 7

c. Air Not Available (Locked Out) pg 8

7. Air Request Cancel pg 9

8. 400Hz Power Request pg 10-12

a. 400Hz Available pg 11

b. 400Hz Unavailable (Locked Out) pg 12

9. 400Hz power Request Cancel pg 13

10. Time & Date adjust pg 14

11. Backlight Level Control pg 14

Station Control Screen Purpose

Station Ready Station Active

1. The purpose of the Station 42 Control Screen is to provide control of CASS Station 42

(this is typical for Stations 42-45). This is to provide the ability to control the station’s:

a. Air

b. 400Hz power

Descriptions of the Touch Screen functions

2. “Comm Loss”: If the station loses communications with the Maintenance Control;

b. The message displayed will be

3. “Manual Air Override”: If the Air is Manually Overridden at the Station by use of the

Key locked Selector Switch located on the door of the Station Control Enclosure;

a. The display changes to

b. The message displayed will be

4. “Lockout”: If the Station is locked out by the Maintenance Station;

a. The display changes to

b. the message displayed will be

5. “Emergency Stopped”: If the Station is Emergency Stopped by pressing the “Red

Mushroom Head” pushbutton on the door of the Station Control Enclosure;

b. The message displayed will be

6. “Air Request”: Controlled from the Touch Screen.

Touching the button icon.

Pressing this icon requests Air at the station if sufficient air is available:

a. If Sufficient Air is available

i. the display will change to

ii. The button icon changes to

iii. The icon Will be displayed (note the Air Request maybe canceled at any time by touching the icon

iv. The message icons will be;

1.

2.

3.

b. If insufficient Air is available:

i. The display changes to or

ii. The button icon changes to

iii. The message icons will be:

1.

c. If the air is not available (too many stations requested):

i. the display changes to

ii. The button icon changes to

iii. The message icons will be:

1.

7. “Air Request Cancel”: Controlled from the Touch Screen by touching either the or the icons. Pressing either of these icons will cancel the Air at the station.

a. The Display changes to

b. The button icon changes to

c. The message icons will be i.

ii.

iii.

8. “400 Hz Power Request”: Controlled from the touch screen by touching the button icon.

Pressing this icon will request 400 Hz power.

a. If 400Hz power is available:

i. The display changes to

ii. The button icon changes to

iii. The icon Will be displayed (note the 400Hz Request maybe canceled at any time by touching the icon

iv. The message icon changes to:

1.

v. Pressing The button icon will energize the Power Contactor to supply

400Hz power to the station;

1. The display changes to

2. The button icon changes to

3. The message icon changes to:

a.

b.

b. If 400Hz power is unavailable:

i. The display changes to

ii. The button icon changes to

iii. The message icon changes to:

1.

9. “ 400 Hz Request Cancel”: Controlled from the Touch Screen by touching either the or the icons. Pressing either of these icons will cancel the 400

Hz power at the station

a. The Display changes to

b. The button icon changes to

c. The message icon changes to i.

ii.

10. ” Time & Date” Adjustment: The time or date can be adjusted by touching the

(time) or (date) icons. The Time adjustment (typical for Date) is made by touching the icon.

a. This will display the keypad icon

b. The icon will change to

c. Type in the new time

d. Press to enter the new time

e. The keypad will disappear

f. The icon will change to

11. “BACK LIGHT LEVEL” control: Controlled by the icon. This icon controls the Back Light level of the display. The level may be increased or decreased to improve the visibility of the display, by touching the slider in the BACK LIGHT LEVEL icon

Maintenance

Maintenance Description

Table of Contents

1. Overview pg 3

2. Touch Screens pg 3

3. Maintenance pg 3

a. Communications pg 3

b. Control System Power pg 3

c. DC power pg 3

d. PLC system pg 4

e. Signals to the Regulators pg 4

f. Location of I/O modules pg 4

g. Loss of communication between the Touch screen & the PLC pg 4

h. Trouble Shooting the PLC pg 4

i. PLC LED codes pg 5

j. Fieldbus Status pg 6

k. Node Status pg 7

l. Fault message via blink code from the I/O-LED pg 8

m. 24vdc Voltage Supply pg 9

n. Replacing the PLC pg 10

o. Downloading the program to the Touch Screen pg 10

1. Overview:

The Typical Control System consists of:

a. The Maintenance Control with;

1. 750-841 or 2: Programmable Logic Controller

2. Ethernet Hub/Media Converter and one or more of the following Communication Links:

i. Ethernet

ii. Fiber-Optic

iii. Radio

3. Touch Screen (if required)

b. The CASS Station with;

1. 750-841 or 2: Programmable Logic Controller

2. Ethernet Hub/Media Converter and one or more of the following Communication Links:

i. Ethernet

ii. Fiber-Optic

iii. Radio

3. Touch Screen

c. The Communication link between the Maintenance Control and CASS Stations is via Modbus/TCP protocol over an Ethernet network and a Communication link (see Functional Description for type of Link)

2. Touch Screens:

The touch screen terminal, consist of several different ‘pages’ that can be accessed using the page navigation touch screen button icons on the display. The graphical view of the airfield layout indicates the status of the controlled circuits.

Each of the runways and taxiways on the screen change colors to indicate the brightness level of that circuit. A color legend appears the touch screen.

3. Maintenance:

The heart of the CASS Control System are the the PLC’s (Programmable Logic Controller) located in the enclosures in the Maintenance Control Area and the CASS Stations. Signals from the PLC Control Enclosure are connected to the Air and 400Hz controls.

a. Communication:

Communication between the system PLCs’, and the Touch Screens is via an “Ethernet network” that consists of Ethernet Hub/Media Converters and Communication links. There is one Ethernet Hub/Media Converter in the Maintenance Control Panel and the CASS Control Panels. The Maintenance Touch Screen terminal and PLC are plugged into the Ethernet Hub/Media Converter in the Maintenance Control console. The CASS Station Touch Screens and PLCs’ are plugged into the Ethernet Hub/Media Converter located in the CASS Stations Control enclosures.

b. Control System Power:

The control panels are supplied with 120vac from the breaker panels located at each location. The hot leg of the incoming power goes through a 10 Amp circuit breaker

c. DC Power:

24vdc power is supplied to the controls by a 24vdc power supply at each location. The 120vac power to the 24vdc power supply goes through a 2 Amp circuit breaker. The 24vdc Power Supply, supplies 24vdc power to the:

1. Maintenance Station:

a. Touch Screen

b. 750-841 Programmable Logic Controller

c. Ethernet Hub/Media Converter

2. CASS Stations:

a. Touch Screen

b. 750-841 Programmable Logic Controller

c. Ethernet Hub/Media Converter

d. PLC System:

The ‘brain’ of the control system is a Wago 750-841 Programmable Fieldbus Controller, commonly referred to as a PLC or Programmable Logic Controller and is powered from a 24vdc power supply. The PLC communicates with the Touch Screen Terminal over Ethernet cables and receives commands from them on how to control the lighting system and supplies data to the Touch Screen as to System Status. The PLC mounts onto a DIN rail and various Input and Output modules slid onto the DIN rail and connects to the PLC. As each module slides onto the rack a continuous bus is formed by which the PLC communicates to all of the modules. There is also a power bus, which can supply ac or dc power to the modules. The power bus is interrupted in several places by a 750- 612 power supply module which disconnects the power bus from the left and continues the power bus on to the modules on the right of the 750-612 module

1. Input modules: provide information to the PLC about the status of devices in the field

a. The E-Stops

b. 24vdc power ON

c. Generator, etc

2. Output modules: provide signals from the PLC to equipment such as Air Supply Solenoids and 400Hz Power Contactors. Basically, the PLC outputs act as relays to control the regulators, but instead of having toggle switches or rotary switches wired to the coils of the relays they are energized by the program stored in the PLC

e. Location of the I/O modules The majority of the I/O modules (Input and Output Modules) are connected directly to the processor by snapping together one after the other.

f. Loss of communication between touch screen and PLC:

In the upper right hand corner of the Touch Screen there will be a gray box displaying To cycle power on the touch screen, unplug the 24vdc power from the back of the unit and then plug it back in

g. Troubleshooting the PLC

1. During normal operation, the PLC status indicators should be in the following states:

a. LINK: This light should be Green whenever the PLC is physically connected to another device

b. MS: This light should be Green and indicates the Node status (Module Status)

c. NS: This light should be Green and indicates the network status (Network Status)

d. TxD/RxD: This light should be Green and On Steady or flash rapidly when communicating to another

Ethernet device, i.e. the touch screens. If this light is off, you have lost all communication to the other Ethernet devices

e. I/O: Red/Green/Orange indicates the status of the node and signals of the system

f. USR: Red/Green/Orange can be controlled by the users program

If there is no LINK light or no TXD/RXD activity, or if the touch screen is indicating that it has lost communications with the PLC, verify that all of the cabling is still connected and not damaged, including the fiber optic cable and its connectors (if supplied ). If all of the physical connections appear to be ok and you cycled power on the touch screen units, try cycling power on the PLC. There is a 2 Amp circuit breaker on the control panel.

Pressing the breaker will open it and remove the 24vdc power to the PLC. Wait about 15 seconds and press the breaker to close the connection, restoring the power to the PLC. After several seconds the PLC should have booted back up

h. PLC LED Codes:

The controller possesses several LED’s for on site display of the controller operating status or the complete node

Fig 1 (750-841)

1. A differentiation between two LED groups is made:

a. The first group = Fieldbus contains: Solid color LEDs having the designation LINK (green), TxD/RxD

(green) and two color LEDs (red/green) indicating MS & NS) indicating the operating status of the communication via ETHERNET

b. The second group = internal bus consists of the three-color I/O LED (red/green/orange). This LED is used to display the status of the internal bus, i. e. the status of the Fieldbus node

c. The three-color USR-LED can be accessed by a user program in the programmable Fieldbus controller LEDs located on the right-hand side in the coupler power supply section show the status of the supply voltage

2. A blink code displays detailed fault messages. A fault is cyclically displayed using up to 3 different blink sequences:

a. The first blink sequence (approx. 10 Hz) indicates the fault display

b. After a pause, a second blink sequence appears (approx. 1 Hz). The number of blink impulses gives the fault code

c. The third blink sequence (approx. 1 Hz) appears following a further pause. The number of blink pulses indicates the fault argument (where the faulty module is physically located on the node)

i. Fieldbus Status:

The operating status of the communication via ETHERNET is signaled via the top LED group:

1. 750-841 {LINL, MS, NS & TxD/RxD} LINK Meaning Trouble shooting green Link to a physical network exists OFF No link to a physical network Check the Fieldbus connection.

MS

red /green -flashing Self test red The system indicates a not remediable error Restart the Fieldbus coupler by turning the power supply Off & On again. If the error still exists, contact I/O Support green-flashing The system is not yet configures green Normal operation OFF No system supply voltage Check the supply voltage (24V and 0V)

NS

red /green-flashing Self test red The system indicates a double IP-address in the Use an IP address that is not used yet.

network red flashing At least one connection (MODBUS/TCP or Ethernet/IP) announced a Timeout, where the CONTROLLER functions as a target

Restart the Fieldbus coupler by turning the power supply Off & On again. If the error still exists, contact I/O Support green-flashing No connection (MODBUS/TCP or Ethernet/IP).

green At least one connection (MODBUS/TCP or Ethernet/IP is developed (also connection to the Message rout applies)

OFF No IP address is assigned to the system. Assign to the system an IP address by BootP, DHCP or the Ethernet Settings tool

TxD/RxD green Data exchange via ETHERNET taking place OFF No data exchange via ETHERNET

j. Node status:

The operating status of the communication with the internal bus is signaled by the bottom I/O-LED

LED:I/O Meaning Trouble shooting green Fieldbus controller operating perfectly red a) During startup of Fieldbus controller: Internal bus being initialized, Startup displayed by LED flashing fast for approx. 1-2 seconds red b) After startup of Fieldbus controller: Errors, which occur, are indicated by three consecutive flashing sequences. There is a short pause between each sequential.

Evaluate the fault message (fault code and fault argument).

Switching on the power supply

Coupler/ Controller starts up "I/O"-LED is blinking

Test o.k. ?

"I/O"-LED is shining

1st break ready for operation

2nd break

YES

NO

Fig 1 Signal of the LED for indication of the node status

"I/O"-LED

1st flash sequence (Introduction of the error indication)

"I/O"-LED

2nd flash sequence Error Code (INumber of flash cycles)

"I/O"-LED

3rd flash sequence Error Argument (Number of flash cycles)

After overcoming a fault, restart the controller by cycling power

k. Fault message via blink code from the I/O-LED:

The controller starts up after switching on the supply voltage. The “I/O” LED blinks. The “I/O” LED has a steady light following a fault free start-up. In the case of a fault the “I/O” LED continues blinking. The fault is cyclically displayed by the blink code

Fault message via blink code from the I/O-LED:

Fault Code # Fault description Fault code 1: Hardware and Configuration fault

0 EEPROM check sum fault / check sum fault in the parameter area of the flash memory 1 Overflow of the internal buffer memory for the inline code 2 Unknown data type 3 Module type of the flash program memory could not be determined / is incorrect 4 Fault when writing in the FLASH memory 5 Fault when deleting the FLASH memory 6 Changed I/O module configuration determined after AUTORESET

Fault code 2: Fault in programmed configuration 0 Incorrect table entry

Fault code 3: Internal bus command fault 0 No fault argument is put out.

Fault code 4: Internal bus data fault 0 Data fault on internal bus or Internal bus interruption on controller n* (n>0) Internal bus interrupted after I/O module n Fault code 5: Fault during register communication n* Internal bus fault during register communication after I/O module n Fault code 6: Fieldbus specific errors

1 No answer from the BootP server 2 ETHERNET controller not recognized 3 Invalid MACID 4 TCP/IP initialization error

Fault code 7: I/O module is not supported n* I/O module at position n is not supported

Fault code 8: not used 0 Fault code 8 is not used.

Fault code 9: CPU-TRAP error 1 Illegal Opcode 2 Stack overflow 3 Stack underflow

4 NMI

(n*) The number of blink pulses (n) indicates the position of the I/O module. I/O modules without data are not counted (i.e. supply modules without diagnostics).

Example for a fault message: Fault: The 13th I/O module has been removed:” LED starts the fault display:

1. The 1st blink sequence (approx. 10 Hz)

2. The 2nd blink sequence (approx. 1 Hz) follows the first pause. The “I/O” LED blinks four times and thus signals the fault code 4 (internal bus data fault)

3. The 3rd blink sequence (approx. 1 Hz) follows the second pause. The “I/O ERR” LED blinks twelve times.

The fault code 12 means that the Internal Bus is interrupted after the 12th I/O module

l. 24vdc Voltage Supply

1. LED Status:

There are two green LED’s in the controller supply section to display the supply voltage. The upper (A) LED indicates the 24vdc supply for the controller. The lower (B) LED signals the supply to the field side, i.e. the power jumper contacts:

Fig 2a (750-841)

LED Meaning Trouble shooting A green Operating voltage for the system exists.

OFF No operating voltage for the system. Check the supply voltage (24V and 0V).

B or C (dependent on Rev) green Operating voltage for the power jumper contacts exists.

OFF No operating voltage for the power jumper contacts. Check the supply voltage (24V and 0V).

2. 24vdc Connection

a. The WAGO-I/O-SYSTEM 750 requires a 24vdc supply (-15% or +20 %). The power supply is provided via the coupler/controller and, if necessary, in addition via the internal system supply modules (750-613). The voltage supply is reverse voltage protected.

b. The use of an incorrect supply voltage or frequency can cause severe damage to the component.

Fig 3 Power Connections

c. The 24vdc supplies all internal system components, e.g. coupler/controller electronics, Fieldbus interface and bus modules via the internal bus (5vdc). The 5vdc is electrically connected to the 24vdc system supply.

m. Replacing the PLC:

If the cabling is all ok and the touch screens and PLC have been rebooted, try replacing the PLC with a spare

1. Disconnect the +&- 24vdc wires from the module

2. Unlock (loosen) the Module from the Din Rail

3. Remove Module by pulling the Orange Pin straight out

4. Reinsert the Module being careful the align the interlock slots

5. Lock(fix) the module to the Din Rail

6. Reconnect the +&- 24vdc wires to the module

Fig 3

n. Downloading program to Touch Screen:

If one of the Beijer Electronics touch screen is to be replaced with a new one, or if the software on it needs to be replaced with an updated project,

1. Disconnect the 24vdc power

2. Replace the Touch Screen.

3. Apply the 24vdc power

4. After the Touch Screen has powered up, insert (on the left hand side of the Touch Screen) the programmed:

a. Compact Flash memory card into the Compact Flash port

b. Flash USB2 unit into the USB 2 port

5. The program has now been written into non-volatile memory

3. Pull up to remove the Module

2. UNLOCK to remove the Module

4. Align Slots (Top & Bottom) then reinsert the Module

1. Disconnect the wires

6. Reconnect the wires

5. (After reinsertion) to Lock the Module

Compact Flash Port

USB 2Port