HOLLiAS MACS-K System Hardware Overview

1. HOLLiAS MACS-K System Overview

HOLLiAS MACS-K system is designed based on international standards and industry norms. It is composed of K series hardware and MACS V6.5 software. It integrates
advanced control algorithm platforms of various industries and can provide professional and comprehensive integrated solutions according to the automation control needs of different industries.

The K series hardware adopts reliability design technologies such as full redundancy, multiple isolation, thermal analysis, and fault tolerance to ensure that the system can run safely and stably for a long time in complex and harsh industrial field environments.

1. Hardware composition

K-Series hardware includes the following:

power supply equipment;
main controller unit;
I/O equipment;
communication equipment;
prefabricated cables;
Cabinet;

The following figure is a schematic diagram of a main cabinet:

The main configuration list of the main cabinet:

2. Power supply equipment

The field control station is powered by system power supply, field power supply and auxiliary power supply respectively.

Typical power supply diagram:

List of power supplies:

1、K-PW01

K-PW01 is a K series AC power distribution board, which can provide input power distribution for AC/DC power conversion modules.

Features:

Support 110/220 VAC input.
Each output has an independent switch and indicator light.
Built-in redundant high-performance filter can prevent grid interference and frequency converter interference.

Appearance and interface:

1. AC power input interface (AC IN)

The two AC power inputs are mutually redundant: the A line is for the mains power supply, and the B line is for the UPS power supply.

The two interfaces are the same, and one of them is used for illustration.

Schematic diagram of AC power input interface:

2. AC power output interface (AC OUT)

The 10 AC power output interfaces are divided into two groups, each group contains 5 channels.

AC power output definition:

The 10 interfaces are the same, and one of them is used for illustration:

Each output has an on-off switch, and each switch corresponds to an indicator light.

When the I terminal of the switch is pressed, the switch is closed and the indicator light is on.
When the O terminal of the switch is pressed, the switch is disconnected and the indicator light is off.

3. Grounding

Connect the grounding stud to the nearest cabinet with a wire.

The grounding resistance should be <4 Ω.

2、K-PW11

K-PW11 is a K series DC power distribution board, which distributes the DC power output from the AC/DC power conversion module redundantly.

System power and field power: output to K-CUT01, K-BUST01.
DC power status detection: output to K-CUT01, K-BUST01.
Auxiliary Power: Output to K-PW21.

Schematic diagram of K-PW11:

1. DC power input interface (DC IN)

The 8-way DC power input interface is divided into 4 groups, and each group has two lines A and B for mutual redundancy.

Definition of DC power input interface:

The 4 groups of interfaces are the same, and one of them is used for illustration.

Schematic diagram of DC power input interface:

2. Auxiliary power output interface (AUX OUT)

The auxiliary power supply is connected to the power input interface of K-PW21 through the prefabricated cable KX-PW03.

The four interfaces are the same, and one of them is used for illustration.

Schematic diagram of the auxiliary power output interface:

3. DC power status detection output interface (DC STATUS OUT)

Through the DC power supply status detection output interface, the status of the system power supply, field power supply and auxiliary power supply can be uploaded to the IO-BUS module
, and the IO-BUS module will report the fault information to the main controller.

It can be configured to choose whether to perform DC power supply monitoring and alarm.

When wiring, connect to the DC power state input interface of K-CUT01 or K-BUST01 through the prefabricated cable KX-PW02.

Schematic diagram of DC power supply status detection output interface:

Definition of DC power state detection output interface:

4. System power supply and field power output interface (SYS & FLD OUT)

The two interfaces are the same and are mutually redundant. Connect to the DC power input interface of K-CUT01 or K-BUST01 through the prefabricated cable KX-PW01
.

Schematic diagram of the system power supply and field power output interface, one of the interfaces is used for illustration:

Definition of system power supply and field power output interface:

5. Grounding

Connect the grounding stud to the nearest cabinet with a wire.

The grounding resistance should be <4 Ω.

K-PW11 DC Power Distribution Board:

3、K-PW21

K-PW21 is a K series auxiliary power distribution board, which can supply power to digital I/O modules, relays and safety barriers.

features

16 outputs;
Support 24/48 VDC;
Short circuit protection (self-recovery insurance)
Fault indicator;

Appearance and interface:

1. Power input (AUX 24/48 VDC Input)

Connect the prefabricated cable KX-PW03 to the auxiliary power output interface of K-PW11 to realize redundant input of auxiliary power.

The two interfaces are the same, and one of them is used for illustration.

Schematic diagram of the power input interface:

2. Power output (AUX 24/48 VDC Distribution Output)

The 16 interfaces are the same, and one of them is used for illustration.

Schematic diagram of the power output interface:

3. Indicator lights

Each output has a self-recovery fuse (750 mA) and a short-circuit fault indicator light. When the load is short-circuited and the channel current is too large
, the indicator light will light up to show the channel fault.

4. Grounding

Connect the grounding post to the working ground bus bar of the cabinet with a wire.

The grounding resistance should be <4 Ω.

K-PW21 auxiliary power distribution board:

4、HPW2405G

The HPW2405G is a 24 VDC (120 W) power module for converting 220 VAC to 24 VDC.

Features:

Input voltage: 85~264VAC;
Output voltage: 24 VDC@5 A;
Rated power: 120W;
Support redundancy (with redundancy module HPWR01G);
Protection: short circuit/overvoltage/overcurrent/overload/overtemperature/fault alarm;
Power output status indication;

Appearance and interface:

1. 220 VAC power input

L: FireWire

N: neutral line

: Ground

2. 24 VDC power output

+: Positive end

-: negative terminal

3. Power output status relay contact

Dry node output, 30 V@1 A, when the output voltage is greater than 90% of the rated value, the alarm output relay is always closed.

4. DC voltage adjustment potentiometer

The voltage adjustment range is 22~28 VDC. Non-redundant mode: 23.5~24.5 VDC recommended

5. Power output status indicator

On: output is normal

Off: output failure

HPW2405G 24 VDC (120 W) Power Module:

5、HPW2410G

The HPW2410G is a 24 VDC (240 W) power module for converting 220 VAC to 24 VDC.

Features:

Input voltage: 85~264VAC;
Output voltage: 24 VDC@10 A;
Rated power: 240W;
Support redundancy (with redundancy module HPWR01G);
Protection: short circuit/overvoltage/overcurrent/overload/overtemperature/fault alarm;
Power output status indication;

Appearance and interface:

1. 220 VAC power input

L: FireWire
N: neutral line
: Ground

2. 24 VDC power output

+: Positive end

-: negative terminal

3. Power output status relay contact

Dry node output, 30 V@1 A, when the output voltage is greater than 90% of the rated value, the alarm output relay is always closed.

4. DC voltage adjustment potentiometer

Voltage adjustment range 22~28 VDC, non-redundant mode: 23.5~24.5 VDC recommended

5. Power output status indicator

On: output is normal

Off: output failure

HPW2410G 24 VDC (240 W) power supply module:

3. Main controller unit

The main controller receives the field data, and outputs the corresponding control signal according to the control scheme, realizes the control of the field equipment, and provides the data
to the host computer at the same time.

Through the IO-BUS, the main controller communicates with the I/O equipment to realize the collection of field data and the transmission of control data.

Through Ethernet, the main controller communicates with the upper computer to realize uploading of process data and diagnostic data.

Main controller unit list:

1、K-CU01

K-CU01 is the main controller module of K series, which adopts PowerPC architecture CPU widely used in mainstream DCS and security platforms.

Features:

Support redundant configuration;
Support system network (SNET) redundancy;
Support control network (CNET) redundancy;
ECC verification function;
Maximum expansion of 100 I/O modules;

1. Appearance and interface

Description of status indication:

2. Redundancy function

The main controller adopts dual redundant configuration to ensure reliability. One controller is in working state (master), the other controller is in standby
state (slave), and the STANDBY indicator light of the slave is on.

The configuration, data and operating cycles are consistent between the two redundant controllers. The two master controllers receive network data and perform control operations at the same time
, but only one outputs the operation result.

Schematic diagram of K-CU01 redundant working principle:

Cycle automatic synchronization: The master and slave interact and synchronize data every cycle, and the synchronization process does not affect the entire control process.
Non-disruptive switching: When the master fails, if the slave is working normally, the master and slave will be switched. The switching is non-disturbance switching, the switching process will not affect the entire control process, and will not cause disturbance of the output channel.
Real-time diagnosis: Redundant controllers can diagnose their own status in real time and diagnose each other. When the host computer affects the control
In the event of a fault, the slave switches to become the master within 100 ms.
Online replacement: The faulty controller can be replaced online without affecting the entire control process.

Master and slave switching situation:

Manually send redundant switching commands.
Main controller reset.
Primary controller failure.

Among them, the failure of the main controller includes hardware failure, system dual network failure and reading SDB failure, and the severity level of the failure is: hardware failure > system dual network failure > reading SDB failure.

When the master controller fails, the master and slave machines will automatically perform redundancy switching according to the seriousness of the fault, so that the
controller with no fault (or the lightest fault) is always the master and in working condition.

3. Diagnostic function

Main controller diagnostic functions include the following:

Hardware fault diagnosis: local IO-BUS communication transceiver fault diagnosis, internal power supply fault diagnosis, clock diagnosis, redundant network connection status diagnosis, control network connection status diagnosis, power-down protection SRAM diagnosis.
Diagnosis of temperature status (alarm when printed board temperature is higher than 90°C).
Power-down protection Low battery capacity diagnosis (below 2.8 V alarm).

In addition, with the IO-BUS module, information such as the temperature in the control cabinet and the status of each power supply can be obtained.

4. Reset function

There is a reset button (RESET) at the bottom of the main controller, and the main controller can be re-initialized by tapping it lightly with a test pen.

5. Power-down protection

There is a backup battery at the lower part of the main controller, which provides power-down protection function.

When the power-down protection function is turned on, if the main controller suddenly loses power, the project files and some key data that need to be kept after power-down will be
automatically saved.

The power-down protection function is controlled by the 7th bit of the DIP switch DN on the main control panel, and it is disabled by default.

After power failure, if the power failure protection function is activated, then after power on again, the main controller will automatically load the project stored in the controller, and at the same time restore the data items set as power failure protection to the state before power failure.
After power failure, if the power failure protection function is off, then after power on again, the main controller will automatically clear the internal project and data, and work in the state of no project.

The effective working time of the backup battery is not less than 3 years. When the battery capacity is insufficient, the controller will report a low battery alarm message. In this case, battery replacement needs to be completed within 3 months.

When replacing the backup battery, it needs to be carried out when the power supply is restored, so as to avoid data loss in power failure protection.

Battery replacement steps:

Open the battery compartment.
Unplug the battery cable.
Remove the old battery from the cover and install a new battery (K-BAT01).
Connect the cable plug to the socket.
Replace the battery compartment.

6. Configuration settings

Double-click the added module to open the "Device Information" window and set the following parameters:

1) Baud rate

Indicates the rate at which the host controller communicates with I/O modules or third-party devices.

When the main controller communicates with the I/O module as the master station, the communication speed is the value set here.

2) Whether the DP parameter uses the default value

The default selection is Yes, use the default values for the following parameters.

TSL: The range is 52~65,535, and the default is 400.
Minimum station delay: range 1~65,535, default 11.
Maximum station delay: range 1~65,535, default 150.
Transmitter failure/repeater switching time: range 0~255, default 0.
Build time: range 1~255, default 1.
Target cycle time: default 4449, not editable.
GAP update factor: default 10, not editable.
Maximum number of retries: range 1~8, default 2.
Minimum slave station interval: range 1~65,535, default 50.
The maximum request time from the master station to the master station: 500 by default and cannot be edited.
The minimum time required to save the global bus state in dual-port RAM: default 600, not editable.

If you need to select No, change AllowConfig=FALSE in the ShowConfig.ini file under the corresponding project to
AllowConfig=TRUE (the path is ...\HOLLiAS MACS\ENG\USER\Project Name\ProjectConfig\ShowConfig.ini), reopen AT, select No, and the above parameters can be edited.

Note: Please modify the above parameters carefully, otherwise it will lead to unstable or invalid hardware work.

7. Specifications

Basic parameters:

With load capacity:

2、K-CU02

K-CU02 is the main controller module of K series, only applicable to MACS V6.5.3B or later versions.

The difference between K-CU02 and K-CU01 is: K-CU02 supports a computing cycle of 50 ms.

The operating cycle of the main controller determines the maximum configuration of the system, as shown in the table below.

3、K-CUT01

K-CUT01 is the backplane of K series 4-slot main controller.

1. Appearance and interface

Schematic diagram of K-CUT01:

K-CUT01 configuration list:

1) DC power input interface

The two interfaces are the same and are mutually redundant. Connect to the system power supply and field power output interface of K-PW11 through the prefabricated cable KX-PW01
.

Schematic diagram of the DC power input interface, one of the interfaces is used for illustration:

Definition of DC power input interface:

2) DC power supply status detection interface

Connect the DC power status output interface of K-PW11 through the prefabricated cable KX-PW02. The status of the system power supply, field power supply and auxiliary power supply can
be uploaded to the IO-BUS module, and detection and setting can be carried out through software configuration.

Schematic diagram of DC power supply status detection interface:

Definition of DC power state detection interface:

3) IO-BUS interface (8 cores)

The 12 IO-BUS interfaces are divided into two groups, A and B, which are mutually redundant; each group contains 6 channels: A1~A6, B1~B6.

The 12 interfaces are the same, and the system power supply and field power supply are output to each I/O device through the prefabricated cable KX-BUSA(B) and communicated.

Schematic diagram of 8-core IO-BUS interface, one of which is used for illustration:

IO-BUS interface definition:

Each group of IO-BUS interface:

The first 4 channels use on-site power supply 1, and the maximum load of on-site power supply 1 is 240 W.
The last two channels use on-site power supply 2, and the maximum load of on-site power supply 2 is 120 W.

4) IO-BUS extension interface

The two interfaces are the same and are mutually redundant. Connect the IO-BUS expansion input interface of K-BUST01 through the prefabricated cable KX-BUSEX02/04 to realize the inter-cabinet cascading of the IO-BUS bus.

Schematic diagram of the IO-BUS expansion interface, one of the interfaces is used for illustration:

IO-BUS extension interface definition:

5) Timing bus interface

The timing bus interface is connected to the timing bus interface of other control stations through the KX-SYN prefabricated cable. The main controllers at both ends need to be connected with KX-SYNT prefabricated cables to provide terminal matching resistance.

Schematic diagram of the timing bus interface, the appearance of the two interfaces is the same as the definition, and one of the interfaces is used for illustration:

Definition of timing bus interface:

6) Grounding

Use wires to connect the ground copper column on site to the working ground bus bar of the cabinet.

Use wires to connect the system ground copper column to the working ground bus bar of the cabinet.

The protective ground of the backplane is connected to the cabinet by the steel base, and the grounding is realized through the cabinet.

All the above grounding resistances should be <4 Ω.

2. Domain address setting

The domain address ranges from 0 to 14, and is set through the first 5 digits of the DIP switch DN; the first digit is the lowest digit, and the fifth digit is the highest digit
. The value of the 5-bit DIP switch is arranged from high to low, and combined into a binary number, the corresponding decimal number is the domain address.

Decimal domain address =

Among them, Ki=0 means that the i-th DIP switch is turned to the ON position, and Ki=1 means that the i-th DIP switch is turned to the OFF position (i: 0~5).

Schematic diagram of the domain address DIP switch:

Domain address DIP switch definition:

Example: domain_address=13.

Analysis: 13=8+4+1, converted to binary is 1101.

Example of domain address setting:

3. Control station address setting

The range of the control station address is 10~73, and it is set by the first 7 digits of the DIP switch CN; among them, the first digit is the lowest digit, and the seventh digit is the highest digit. The value of the 7-bit DIP switch is arranged from high to low and combined into a binary number, and the corresponding decimal number is the station address.

decimal station address =

Among them, Ki=0 means that the i-th DIP switch is turned to the ON position, and Ki=1 means that the i-th DIP switch is turned to the OFF position (i: 0~7).

Schematic diagram of station address DIP switch:

Station address DIP switch definition:

The station address is only read and valid when the controller is powered on or reset.

Example: Station address=46.

Analysis: 46=32+8+4+2, converted to binary is 101110.

Example of station address setting:

4. IO-BUS address setting

Setting the address of the IO-BUS module can realize the communication with the controller. Each IO-BUS module corresponds to an address, the range is: 2~7, 112~117.

IO-BUS module address = base address + offset address

Base address: 0, 110
Offset address: 2~7

There is a jumper cap in the base address area, which is used to set the base address.

There is a jumper cap in the offset address area, which is used to set the offset address.

Schematic diagram of IO-BUS address:

IO-BUS address definition:

Example 1: IO-BUS module address=3. Then the base address is 0 and the offset address is 3.

Example of IO-BUS module address setting:

Example 2: IO-BUS module address=114. Then the base address is 110 and the offset address is 4.

Example of IO-BUS module address setting:

5. Short circuit protection

The two fuse compartments correspond to two groups of IO-BUS buses A and B, and each system power supply (S) and field power supply (F) is equipped with a one-time replaceable fast-blow fuse. When an abnormal phenomenon such as overcurrent or short circuit occurs in a certain power supply, the fuse will play a role in protecting the system.

Fuse diagram:

Technical indicators:

4. I/O equipment

The I/O device collects analog or digital signals from the field, converts these signals for processing by the main controller, or outputs the
processed signals of the main controller to the field.

I/O devices communicate with the main controller through the IO-BUS bus.

The main components of the I/O device are:

I/O modules
I/O base
terminal board
safety barrier

1. I/O module

The I/O module mainly implements the signal conversion function, which can be divided into the following two categories:

Analog I/O module;
Digital I/O modules;

List of I/O modules:

1. K-AI01

K-AI01 is an 8-channel analog input module of K series.

Features:

Full scale 0~22.7 mA;
Support two-wire system/three-wire system/four-wire system;
Support redundant configuration;
Input overcurrent protection;
Board fault diagnosis;
Namur diagnosis;
Abundant indicator lights;
Channel resistance to 220 VAC (reinforced base);
hot swap;
Anti-mixing design;

1) Appearance and interface

Schematic diagram of K-AI01:

Status indication:

Slow flashing: 0.5 s on, 1.5 s off

Fast flashing: 0.5 s on, 0.5 s off

In redundant mode, the channel lights of the master module indicate the signal status of the channel loop, and the channel lights of the slave modules are all off.

2) Redundancy function

K-AI01 supports redundant configuration. Installing two K-AI01 modules in one K-AT21 base can realize module redundancy.

An example of module redundancy is shown in the figure below.

In module redundancy configuration, the module that establishes communication first is the master module, and the module that establishes communication later is the slave module.
The master module and the slave module can be distinguished according to the state of the PWR indicator .

When the master module fails and the slave module is normal, non-disruptive switching is performed; otherwise, no switching is performed.

The module has a fault memory function, so the same fault will only trigger one switching.
By plugging and unplugging the module, the fault memory of the module can be cleared.

3) Diagnostic function

The diagnosis reported by the module includes device diagnosis and channel diagnosis.

When a fault is diagnosed, the module will report the diagnostic information to the operator station and display it on OPS.

After the fault is recovered, the module will report the recovery information to the operator station and display it on OPS.

In redundant configuration, all channel diagnostic data are reported by the main module.

(1) Equipment diagnosis

Equipment diagnosis includes whether the on-site power supply is faulty, whether the IO-BUS redundant network is faulty, and module board-level fatal faults, etc.

When the module is powered on, it performs self-test and establishes communication. After the communication is established, the module will
detect the IO-BUS communication network and field power in real time.

(2) Channel diagnosis

Channel diagnosis reports the fault channel number and fault type. Fault type and judgment condition:

Disconnection: I<0.75mA
Namur underrange: 0.75 mA<I<3.6 mA for 4 s
Namur over-range: 21 mA<I<22.5 mA and hold for 4 s
Short circuit: I>22.5mA

Diagram of channel diagnosis:

4) Electrical principles

Principle block diagram:

5) Instructions for use

The I/O module needs to be used with the I/O base. Please select the base type according to the field application situation and the base characteristics.

Base selection list:

Precautions:

It is forbidden to connect the voltage exceeding ±30 VDC to the terminal, otherwise the module will be damaged.
When the input signal exceeds the configured range and is less than the maximum range of the module, it can continue to measure and report the collected data. But when the input signal exceeds the maximum range of the module, it will be limited to maintain the maximum range reported value.
The module has the function of current limiting protection, but it is necessary to avoid short-circuiting of 8 channels at the same time, so as to avoid excessive heating of the current limiting circuit.
Channels that are not used in the module are recommended to be disabled in the configuration to avoid circuit break alarms.

6) Configuration settings (under K-CU01/K-CU02 controller)

Double-click the added module to set the following parameters:

Device Information:

Base type: Select the corresponding base according to the hardware configuration.
All-channel filtering parameters: through industrial frequency filtering, industrial power frequency can be filtered out to prevent and suppress interference. according to
In the case of the scene, select the filter parameters.

Measuring point information:

SIGTYPE (signal type): Select the signal type according to the site situation.
Channel status: including disabling the channel (the channel reports a value of "0" and no diagnostic information), enabling the channel and normal diagnosis (the channel is valid and performing open circuit and short circuit diagnosis), enabling the channel and Namur diagnosis (the channel is valid and performing normal diagnosis and Namur underrange and overrange diagnosis).
Channel data collection cycle: each channel can set a separate data collection cycle.

7) Configuration settings (under K-CU03 controller)

Double-click the added module to set the following parameters.

Configuration settings window:

Basic Information:

Base type: Select the corresponding base according to the hardware configuration.

Device parameters:

All-channel filtering parameters: through industrial frequency filtering, industrial power frequency can be filtered out to prevent and suppress interference. According to the situation on site, select the filter parameters.

Select the channel under the Module Information tab, click Configure Parameters, and set the following parameters in the Configuration Parameters window:

Channel status: including disabling the channel (the channel reports a value of "0" and no diagnostic information), enabling the channel and normal diagnosis (the channel is valid and performing open circuit and short circuit diagnosis), enabling the channel and Namur diagnosis (the channel is valid and performing normal diagnosis and Namur underrange and overrange diagnosis).
Channel data collection cycle: each channel can set a separate data collection cycle.

Measuring point information:

SIGTYPE (signal type): Select the signal type according to the site situation.

Technical indicators:

2. K-AIH01

K-AIH01 is a K series 8-channel analog input module with HART.

The difference between K-AIH01 and K-AI01 is: K-AIH01 supports HART 5 communication protocol.

Schematic diagram of K-AIH01:

See K-AI01 for details.

2, I/O bottom seat

The I/O base mainly realizes functions such as on-site signal access and safety protection.

Terminal block: directly connected to field signal cables for wiring inside the cabinet.
DB37 interface: Connect to the terminal board or safety barrier, which can be used for cross-cabinet wiring.

List of I/O bases:

1. K-AT01

K-AT01 is an 8-channel AI and AO stand for K series.

Appearance and interface:

1) Wiring area

VT terminals (VT+, VT-): used for field power detection.
NC terminal: Not used.

2) I/O module address bin

Each I/O module corresponds to an address, the range is: 10~109.

The upper row of jumpers represents tens digits, and the value range is 1~10; the lower row of jumpers represents ones digits, and the value range is 0~9.

Schematic diagram of I/O module address bin:

Please set the address of the I/O module before installing the base. After the address is set, please cover the cover of the address compartment of the I/O module. Do not change the address of the I/O module when the system is working normally.

Example:

(1) If the module address is 23, short the tens digit representing number 2 with a jumper, and the ones digit 3 with a jumper wire.

Example of I/O module address setting:

(2) If the module address is 106, short the tens digit representing number 10 with a jumper, and the ones digit representing number 6 with a jumper wire.

Example of I/O module address setting:

3) Fuse compartment

There is a pluggable fast-acting fuse inside to protect the on-site power supply.

4) IO-BUS A interface (6 cores)

The two IO-BUS interfaces are the same and are mutually redundant. The IO-BUS A interface is connected to the prefabricated cable KX-BUSA, and the IO-BUS B interface is connected to the
prefabricated cable KX-BUSB.

Schematic diagram of 6-core IO-BUS interface, one of which is used for illustration:

6-core IO-BUS interface definition:

The IO-BUS interface adopts an anti-confuse design. The directions of interfaces A and B are different, which can effectively avoid human errors.

Schematic diagram of IO-BUS cable connection steps:

5) IO-BUS B interface (6 cores)

6) Anti-mixing

Anti-mix pins are used to prevent insertion of modules that do not match the base.

There are anti-mix pins on the I/O module and I/O base, and the coding range is 1~8.

The anti-mixing pin on the I/O module is a female mold, and each type of electrically compatible module is uniquely assigned a code, which is fixed at the factory and cannot be changed; the anti-mixing pin on the I/O base is a male mold, and the code can be changed by rotation
.

Schematic diagram of anti-mixing sales:

Please do not use violence when inserting the module. When you find that the module cannot be inserted smoothly, please check the position of the anti-mixing pin. The number of anti-mixing pins is limited and cannot prevent all wrong insertion. Please read the module instruction manual before use to ensure that the module and the base can match.

Inserting a module that does not match the base may result in damage to the device.

7) I/O module slot

Used to connect I/O modules.

K-AT01 can be used with a variety of I/O modules, the list of supported I/O modules:

Matching K-AI01/K-AIH01 wiring diagram:

Terminal definition:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

The ground potential of the four-wire instrument end and the DCS side should be equal.

Supporting K-AO01/K-AOH01:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

Terminal definition:

Each channel provides a current test terminal, which is convenient for on-site troubleshooting without affecting the normal operation of the on-site load.

Method: use the multimeter to measure the current, connect the positive test lead to the Dn terminal, and the negative test lead to the An terminal.

Technical indicators:

2. K-AT11

K-AT11 is an 8-channel AI and AO booster stand for K series.

The difference between K-AT11 and K-AT01 is: K-AT11 has a channel anti-220 VAC function

Schematic diagram of K-AT11:

See K-AT01 for details.

3. K-DOT01

K-DOT01 is a K series 16-channel DO base.

Appearance and interface:

1) Wiring area

Schematic diagram of the wiring area:

DB37 pin definition:

VI terminals (VI+, VI-): auxiliary power input.

24V terminals (24V +, 24V -): field power output.

2) I/O module address bin

3) Fuse compartment

J5 jumper area, short-circuit pins 1 and 2 when matching with K-TC01, and short-circuiting pins 1 and 3 when matching with other I/O modules (default).

The two black fuses are fuses for the positive and negative terminals of the output power supply, with a current limit of 1.25 A, and are pluggable.

Schematic diagram of the fuse compartment:

4) IO-BUS A interface (6 cores)

5) IO-BUS B interface (6 cores)

6) Anti-mixing

7) I/O module slot

Used to connect I/O modules.

K-DOT01 can be used with a variety of I/O modules, the list of supported I/O modules:

Matching FM138-SSRR Wiring method:

For DC loads, the FM138-SSRR needs to be equipped with a Crydom CMX60D5 relay.
For AC loads, the FM138-SSRR needs to be equipped with a Crydom CX480D5 relay.

Notice:

The two black fuses in the K-DOT01 fuse compartment must be removed.
The J2 terminal of FM138-SSRR is prohibited from wiring.

Solid state relay parameters:

Precautions:

When the K-DOT01 base is powered on, the connection of the DB37 cable must be done as shown in the figure below.

To disconnect the DB37 cable, proceed in reverse:

When connecting the DB37 cable, cut in from the left side first.
When disconnecting the DB37 cable, do so from the right side first.
The above requirements must be strictly followed to avoid damage to the K-DOT01 base.

Technical indicators:

4. K-PIT01

K-PIT01 is a K series 6-channel pulse input base.

Appearance and interface:

1) Wiring area

Terminal definition:

2) I/O module address bin

3) Fuse compartment

4) IO-BUS A interface (6 cores)

5) IO-BUS B interface (6 cores)

6) Anti-mixing pin

7) I/O module slot

Used to connect I/O modules.

K-PIT01 is used with K-PI01, the list of matching I/O modules.

Depending on the field instrument, the following power supply methods can be selected:

On-site power supply mode: only supports instruments with a working voltage of 24 VDC.
External power supply mode: supports instruments with working voltage of 5/12/24 VDC.
Independent power supply mode of the meter: supports the meter whose working voltage is 5/12/24 VDC.

Dry contact signal:

Wiring diagram (on-site power supply mode).

Wiring diagram (external power supply mode).

Two-wire proximity switch:

Wiring diagram (on-site power supply mode).

Wiring diagram (external power supply mode).

PNP type proximity switch:

Wiring diagram (on-site power supply).

Wiring diagram (external power supply).

NPN type proximity switch:

Wiring diagram (on-site power supply).

Wiring diagram (external power supply).

Three-wire voltage pulse signal:

Wiring diagram (on-site power supply).

Wiring diagram (external power supply).

Wiring diagram (instrument power supply).

Three-wire current pulse signal:

Wiring diagram (on-site power supply).

Wiring diagram (external power supply).

Wiring diagram (instrument power supply).

Four-wire voltage pulse signal:

Wiring diagram (instrument power supply).

Technical indicators:

3, terminal board

It is connected to the I/O base through prefabricated cables to realize signal isolation and conversion functions.

Terminal board list:

1. K-AIR01

K-AIR01 is a K series 16-channel two/four-wire current input terminal board, which can be used with the following bases:

K-AT23
K-DOT01

Appearance and interface:

DB37 interface (male seat):

Terminals:

An terminal: Two-wire system 24 V power supply output negative terminal/four-wire system current input positive terminal.
Bn terminal: Four-wire current input negative terminal.
Cn terminal: two-wire 24 V power supply output positive terminal.
VT terminals (VT+, VT-): used for field power detection.
PE terminal: ground.
NC terminal: Not used.

The terminal board needs to be connected to the corresponding I/O base for use, and the list of supporting I/O modules and bases.

Matching K-AT23 wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

The ground potential of the four-wire instrument end and the DCS side should be equal.

Supporting K-DOT01, wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

The ground potential of the four-wire instrument end and the DCS side should be equal.

Technical indicators:

2. K-AIR02

K-AIR02 is a K series 16-channel three-wire current input terminal board, which can be used with the following bases:

K-AT02
K-AT21
K-AT23
K-DOT01

Appearance and interface:

DB37 interface (male seat):

Terminals:

An terminal: current input positive.
Bn terminal: current input negative.
Cn terminal: 24 VDC external power supply output.
VI terminals (VI+, VI-): 24 VDC external power supply input (must be provided by the on-site power supply of the DCS cabinet).

The terminal board needs to be connected to the corresponding I/O base for use, and the supporting I/O modules and bases are listed.

K-AI01/K-AIH01, supporting K-AT02/K-AT21/K-DOT01:

Wiring diagram (8-channel mode).

Wiring diagram (8+8 channel mode).

Notice:

The 24 VDC external power supply must be provided by the on-site power supply of the DCS cabinet.
The cable shield is grounded at one end on the DCS side (cabinet busbar).
The DB37 cable is a Y-cable, model number KX-AIR02-5/10/20. Among the two DB37 ports connected to the base, the ones with red bushings are CH1~8, corresponding to channels 1~8 of K-AIR02; the ones with blue bushings are CH9~16, corresponding to channels 9~16 of K-AIR02.

K-AI03/K-AIH03, matched with K-AT23, wiring diagram:

The 24 VDC external power supply must be provided by the on-site power supply of the DCS cabinet.

The cable shield is grounded at one end on the DCS side (cabinet busbar).

K-AI03/K-AIH03, matched with K-DOT01, wiring diagram:

Notice:

When matching the K-DOT01 base, you must use K-DOT01-C or later models, otherwise the K-AIR02 terminal board will be damaged!
The 24 VDC external power supply must be provided by the on-site power supply of the DCS cabinet.
The cable shield is grounded at one end on the DCS side (cabinet busbar).
The orange terminal of the K-DOT01 base is not wired.

Technical indicators:

3. K-DIR01

K-DIR01 is a K series 16-channel DC 24 V relay input terminal board, which can be used with the following bases:

K-DIT02
K-DIT21
K-DOT01

Appearance and interface:

Diagram of DB37 interface:

Terminals:

Schematic diagram of wiring terminals (channel 1~8).

Schematic diagram of wiring terminals (channel 9~16).

An terminal: positive terminal of the channel.
Bn terminal: negative terminal of the channel.
24V terminals (24V+, 24V-): 24 VDC auxiliary power input. Among them, 24V1+ and 24V1- supply power to channels 1~8, and 24V2+ and 24V2- supply power to channels 9~16.

Electrical principle:

The terminal board needs to be connected to the corresponding I/O base for use.

List of supporting I/O modules and bases:

1) Supporting K-DIT02/K-DIT21

Dry contact, wiring diagram:

24V1+, 24V1- supply power to channels 1~8, 24V2+, 24V2- supply power to channels 9~16.

NPN type proximity switch:

24V1+, 24V1- supply power to channels 1~8, 24V2+, 24V2- supply power to channels 9~16.

2) Supporting K-DOT01

Dry contact, wiring diagram:

24V1+, 24V1- supply power to channels 1~8, 24V2+, 24V2- supply power to channels 9~16.

NPN type proximity switch:

24V1+, 24V1- supply power to channels 1~8, 24V2+, 24V2- supply power to channels 9~16.

Technical indicators:

K-DIR01

relay

4. K-UR01

K-UR01 is a K series universal adapter plate, which can be used with the following bases:

K-AT02
K-AT21
K-AT13
K-AT22
K-DIT02
K-DIT21
K-TT21
K-DOT01

Appearance and interface:

DB37 interface:

Terminals:

The corresponding relationship between the terminal block and the DB37 interface is shown in the table below:

The terminal board needs to be connected to the corresponding I/O base for use.

List of supporting I/O modules and bases:

Supporting K-AT02/K-AT21

K-UR01 terminal description.

K-AI01/K-AIH01, wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

The ground potential of the four-wire instrument end and the DCS side should be equal.

K-AO01/K-AOH01, wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

Supporting K-AT13/K-AT22

K-UR01 terminal description:

Current signal wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

Voltage signal wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

Supporting K-DOT01

K-AI01/K-AIH01：

K-UR01 terminal description.

Wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

The ground potential of the four-wire instrument end and the DCS side should be equal.

When matching K-AI01/K-AIH01, the K-DOT01 base does not support two-wire instruments.

K-AO01/K-AOH01：

K-UR01 terminal description.

Wiring diagram:

The cable shield is grounded at one end on the DCS side (cabinet busbar).

Technical indicators:

5. Communication equipment

1. IO-BUS equipment

IO-BUS is the control network of MACS-K system, used to connect the main controller and I/O equipment, and realize the data exchange between the two.

List of IO-BUS devices:

Star, single cabinet (I/O modules≤60):

Star, multi-cabinet (I/O modules≤100):

Bus type, single cabinet (I/O modules≤30):

Hybrid, multi-chassis (I/O modules≤100):

1. K-BUS02

K-BUS02 is a K series 8-channel star IO-BUS module, which can implement star topology for IO-BUS.

Channel 1~6 (COM 1~6): I/O module communication port.
Channel 7 (COM 7): Extended communication input port.
Channel 8 (COM 8): Extended communication output port.

Features:

hot swap
IO-BUS link detection
DC Power Status Detection
Cabinet temperature detection

K-BUS02 appearance and interface:

Status indication:

Detection function:

Link detection function: including IO-BUS bus long-term logic "0" fault, and report the fault information to the main controller.
DC power supply status detection: With K-PW11, it can detect the DC power supply status. (By default, the first 6 channels are enabled, and the last 4 channels are disabled)
Cabinet temperature detection: The temperature measurement range is -20°C~60°C, and the temperature data is reported to the main controller and displayed on the OPS system status diagram.

When K-BUS02 is installed on K-CUT01, it has repeater function:

Each IO-BUS communication port can independently drive a network segment, and the segments are logically isolated. There are 6 network segments locally, and each network segment can connect 10 I/O modules.
Support out-of-cabinet expansion, up to 3 levels of cascading. When 2-level cascading, the maximum baud rate is 3 Mbps; when 3-level cascading, the maximum baud rate is 1.5 Mbps.

When K-BUS02 is installed on K-BUST01, it has hub function:

Realize the topology of the network structure, and reserve the expansion interface outside the cabinet.

Configuration settings (under K-CU01/K-CU02 controller)

Double-click the added module to set the following parameters:

Power status detection parameters:

Communication network segment fault diagnosis parameters:

Configuration settings (under K-CU03 controller)

Double-click the added module to set the following parameters:

Power status detection parameters:

Communication network segment fault diagnosis parameters:

Technical indicators:

2. K-BUST01

K-BUST01 is a single-slot IO-BUS backplane, used to connect IO-BUS modules in the expansion cabinet.

Appearance and interface:

K-BUST01 configuration list:

Technical indicators:

2. Bridge/gateway device

1. K-DP02

K-DP02 is a K series DP Y-link bridge communication module, which is used to realize the network conversion between the upper redundant Profibus-DP master system and the lower non-redundant Profibus-DP equipment system.

features

Board fault diagnosis;
Abundant indicator lights;
Support redundant mode (base redundancy);
Electrical load capacity ≤ 29 on-site DP devices;
hot swap;
Anti-mixing design;

Appearance and interface:

Indicator light description:

In redundant mode, the DP light of the master module indicates the data communication status, and the DP light of the slave module goes out.

The diagnosis function of K-DP02 includes equipment diagnosis and field side communication fault diagnosis.

When a fault is diagnosed, the module will report the diagnostic information to the operator station and display it on OPS.

After the fault is recovered, the module will report the recovery information to the operator station and display it on OPS.

1) Device diagnosis

Equipment diagnosis includes whether the on-site power supply is faulty, whether the IO-BUS redundant network is faulty, and module board-level fatal faults, etc.

2) On-site communication fault diagnosis

When the K-DP02 communicates with the field instrument normally, the DP indicator is flashing, indicating that there is data exchange; if the DP indicator does not
flash, there may be the following reasons:

Poor contact of communication cable
Incoming and outgoing wires on the instrument side are reversed
Power Interference
D1+ and D2+ or D1- and D2- of the redundant base K-PAT21 are not shorted
Slave address error

Electrical principle:

The communication module needs to be used with the communication base. Please select the base type according to the field application situation and the base characteristics.

Base selection:

Precautions:

Only RS485 electrical interface is supported.
The third-party device address range is 3~31.
It is forbidden to connect the voltage exceeding ±30 VDC to the terminal, otherwise the module will be damaged.
The number of mounted K-DP02 modules is related to the main control: Since the communication data buffer capacity of the main controller is 3.5 KB for input data area and 3.5 KB for output data area, the total input data of all slave modules (including Modbus bridge/gateway modules) mounted under the main control must be ≤3.5 KB, and the total output data must be ≤3.5 KB.

configuration settings

1) Import third-party equipment

Step 1: Right-click on [Third-party DP/PA Device] in the "Device Library", and click [Import] in the pop-up menu.

Import third-party devices:

Step 2: Select the GSD file of the third-party device and click Open.

Step 3: Select the type (DP or PA) according to the device and click OK.

Step 4: Under the corresponding category of [Third Party DP/PA Device], you can see the device you just imported.

2) Add third-party devices

Step 1: Double-click the added K-DP02 module to enter the "Device Information" and "DP/PA Device Information" windows.

Step 2: Double-click [Configure DP/PA Device], select a third-party device from the left window, enter the number to add, and click >> to add it to the right window. Click OK.

Step 3: Under the "DP/PA Device Information" window, the third-party device just added appears.

3) Configure third-party devices

Step 1: Under the "DP/PA Device Information" window, double-click the third-party device to enter the "Device Information" window:

Step 2: From the Device Properties item, double-click to enter the Device Properties window.

Step 3: Select a module from the optional module area on the left, and click >> to add it to the added module area on the right.

Step 4: Select the added module, click Properties, and enter the "Submodule Properties" window.

Station address: The address of the third-party device, the range is 3~31, and the default is 3.

Other parameters: vary with third-party devices, please set them according to specific application situations.

4) K-DP02 device information configuration

In the "Device Information" window of K-DP02, set the following parameters:

(1) Terminal board type

According to the hardware configuration, select the corresponding terminal board.

(2) Device properties

Enter the Device Properties window by double-clicking on the configuration.

Input/output selection, generally no need to set.

The sum of input data≤244 bytes (up to 227 bytes can be configured).
The sum of the output data is ≤244 bytes (up to 244 bytes can be configured).

User parameters:

Synchronous mode: Indicates that the output is synchronous, and the output data of the slave station is locked in the current state until the next synchronous command is received. Checked by default.
Freeze mode: that is, lock mode, which means input synchronization, and the input data of the slave station is locked in the current state until the next freeze command is received. Checked by default.
Fail Safe: Checked by default.
DP interrupt mode: DPV0 means the basic DP function and does not support aperiodic communication; DPV1 means it has aperiodic communication function and includes all the functions of DPV0.
Baud Rate: The communication rate between K-DP02 and third-party DP devices, the default is 500 kbps.

Technical indicators:

6. Timing function

The timing sources are as follows:

GPS: Use GPS as the source of time calibration.
FM197: Use Hollysys FM197 time synchronization hub as the time calibration source.
Soft calibration: take the computer system time as the calibration source.
NTP: Use NTP server as the source of time calibration.

Example of inter-domain timing:

Intra-domain timing example 1 (without SOE module):

Step 1: Time synchronization on the main historical station

Single-domain situation: The main historical station synchronizes the time with the time calibration source.
Multi-domain situation: the master historical station of the domain with the smallest number synchronizes time with the time correction source, and the master historical stations of other domains synchronize time with the master historical station of the domain with the smallest number.

Step 2: Synchronize the time from the history station, operator station, engineer station, and designated controller (default is the smallest controller with both networks in good condition) to the history station of the domain in each domain, and the period is 60 s.

Step 3: Other controllers in each domain synchronize the time with the designated controller in this domain, and the period is 60 s. If there is an SOE module under the controller, you need to use a hard time calibration cable (KX-SYN, KX-SYNT), and follow the steps below.

Step 4: The SOE module under the control station of each domain synchronizes the time with the corresponding controller.

Intra-domain timing example 2 (with SOE module):

In the case of multiple domains, if the time calibration source is GPS/FM197/soft time calibration, then the domain with the time calibration source must be the smallest domain.

When GPS or FM197 is used as the timing source, the master and slave historical stations need to be connected to the timing source at the same time to form redundancy.

For the configuration setting of the history station, refer to the manual of the general engineering control.

Conditions for multi-domain timing: the projects in these domains belong to the same project, and the networks are interoperable.

The accuracy is 0.5 ms when using the hard timing line (KX-SYN, KX-SYNT), and the accuracy is 10~100 ms when not in use.