Symphony Plus

S+ Control: NTCS04
Controller/Station Termination Unit
User Manual

Symphony Plus
NOTICE
This document contains information about one or more ABB products and may include a description of or a
reference to one or more standards that may be generally relevant to the ABB products. The presence of any
such description of a standard or reference to a standard is not a representation that all of the ABB products
referenced in this document support all of the features of the described or referenced standard. In order to
determine the specific features supported by a particular ABB product, the reader should consult the product
specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectual property in the
ABB products described in this document.

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB, and
the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and may be used, copied,
or disclosed only in accordance with the terms of such license. This product has been designed to meet the
requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC. Refer to the
Specifications section in this manual for status of agency certifications

TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2011-2012 ABB.
All rights reserved.

Release: June 2012

Document number: 2VAA001695
Preface

The NTCS04 Controller/Station Termination Unit is a Harmony rack I/O device that is part of the Symphony Enterprise
Management and Control System. It provides connections for a Harmony controller, IMCIS12 Control I/O or IMQRS12
Quick Response module, and IISAC01 Analog Control Stations. Serial link connections for daisy-chaining additional
NTCS04 termination units are also provided.

This user manual explains the NTCS04 termination unit specifications and operation. It details the procedures necessary to
complete setup, installation, maintenance, repair, and replacement of the termination unit.

NOTE: The NTCS04 termination unit is fully compatible with existing INFI 90 OPEN Strategic Enterprise Management
Systems.
Support Services

ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.

ABB has modern training facilities available for training your personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and scheduling.

Additional copies of this instruction, or other instructions, can be obtained from the nearest ABB sales office at a reasonable
charge.
Trademarks and Registrations
Registrations and trademarks used in this document include:

INFI-90® Registered trademark of ABB.

Symphony™ Plus Trademark of ABB S.p.A.
 TABLE OF CONTENTS

TABLE OF CONTENTS

Safety Summary.......................................................................................................1

About This Book ......................................................................................................3

Document Conventions .......................................................................................3
Information and Tip Icons....................................................................................3

1. Introduction.................................................................................................... 1-1
1.1 Overview ..............................................................................................................1-1
1.2 Mounting Hardware.............................................................................................1-1
1.3 Intended User ......................................................................................................1-2
1.4 User Manual Content ..........................................................................................1-2
1.5 How to use this Manual ......................................................................................1-2
1.6 Document Conventions ......................................................................................1-2
1.7 Reference Documents.........................................................................................1-2
1.8 Related Nomenclature ........................................................................................1-3
1.9 Specifications ......................................................................................................1-3

2. Installation ...................................................................................................... 2-1

2.1 Introduction .........................................................................................................2-1
2.2 Special Handling .................................................................................................2-1
2.3 Unpacking and Inspection..................................................................................2-1
2.4 Setup/Physical Installation .................................................................................2-1
2.4.1 Dipshunt Configuration ....................................................................................2-1
2.4.2 Fuse Installation...............................................................................................2-4
2.5 Termination Unit Installation ..............................................................................2-4
2.5.1 Mounting ..........................................................................................................2-5
2.5.2 Termination Unit Cables...................................................................................2-6
2.5.3 Power Wiring....................................................................................................2-8
2.5.4 Terminal Block Wiring ......................................................................................2-8
2.6 Connector Pinouts ..............................................................................................2-9
2.7 I/O Signal Connections .....................................................................................2-10
2.8 Installation Complete ........................................................................................ 2-11

3. Maintenance ................................................................................................... 3-1

3.1 Introduction .........................................................................................................3-1
3.2 Preventive Maintenance Schedule ....................................................................3-1
3.3 Equipment and Tools Required..........................................................................3-1
3.4 Preventive Maintenance Procedures.................................................................3-1
3.4.1 Printed Circuit Board Cleaning ........................................................................3-2

2VAA001695 i
TABLE OF CONTENTS

3.4.2 Checking Connections .....................................................................................3-2

4. Repair and Replacement ............................................................................... 4-1

4.1 Introduction .........................................................................................................4-1
4.2 Fuse Replacement...............................................................................................4-1
4.3 Termination Unit Replacement...........................................................................4-1

ii 2VAA001695
 LIST OF TABLES

LIST OF TABLES

Table 1-1 Reference Documents ...............................................................................1-3

Table 1-2 Related Nomenclature ...............................................................................1-3
Table 1-3 NTCL01 Specifications ..............................................................................1-4
Table 2-1 NTCL01 Jumpers (J5 through J10)) ..........................................................2-2
Table 2-2 NTCL01 Cable Applications ......................................................................2-4
Table 3-1 Preventive Maintenance Schedule ............................................................3-1
Table 4-1 Spare Parts List .........................................................................................4-1

2VAA001695 iii
LIST OF TABLES

iv 2VAA001695
 LIST OF FIGURES

LIST OF FIGURES

Figure 1-1 Harmony Rack I/O Architecture................................................................. 1-1

Figure 1-2 Mounting Hardware ................................................................................... 1-1
Figure 2-1 Termination Unit Layout ............................................................................ 2-2
Figure 2-2 Switching Hot vs Switching Neutral........................................................... 2-4
Figure 2-3 Termination Unit Installation...................................................................... 2-5
Figure 2-4 Chassis Common Connection................................................................... 2-5
Figure 2-5 Controller to IISAC01 Station Cable Connections..................................... 2-6
Figure 2-6 Controller to I/O Module Cable Connections............................................. 2-7
Figure 2-7 Terminal Assignments............................................................................... 2-9

2VAA001695 v
LIST OF FIGURES

vi 2VAA001695
Safety Summary

The following table categorizes the various safety precautions to be followed when using the NTCS04 termination unit:

Safety Precaution Description

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling

precautions as described in section 2- Installation of this
user manual.

GENERAL WARNINGS Equipment Environment

All components, whether in transportation, operation or
storage, must be in a non-corrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that
contact with energized parts is avoided when servicing
SPECIFIC WARNINGS Verify the main power, field power, and power entry panel
circuit breakers/switches are turned off before starting
installation, retrofit, upgrade, or wiring procedures. Failure
to do so could result in severe or fatal shock. Do not turn
the power on until the installation, retrofit, upgrade, or
wiring procedures are complete. (Refer to sub-section
2.5.3- Power Wiring of this user
manual, where this specific warning statement is
applicable)

Never clean electrical parts or components with live power

present. Doing so exposes you to an electrical shock
hazard. (Refer to sub-section
3.4.1- Printed Circuit Board Cleaning of this user
manual, where this specific warning statement is
applicable)

Wear eye protection whenever working with cleaning

solvents.When removing solvents from printed circuit
boards using compressed air, injury to the eyes could
result from splashing solvent as it is removed from the
printed circuit board. (Refer to sub-section 3.4.1- Printed
Circuit Board Cleaning of this user manual, where this
specific warning statement is applicable)

There are exposed AC and DC connections inside the

cabinet. These exposed electrical connections present a
shock hazard that can cause injury or death. (Refer to
sub-section 3.4.2- Checking Connections of this user
manual, where this specific warning statement is
applicable)

If input or output circuits are a shock hazard after

disconnecting system power at the power entry panel,
then the door of the cabinet containing these externally
powered circuits must be marked with a warning
stating that multiple power sources exist. (Refer to sub-
section 3.4.2- Checking Connections of this user manual,
where this specific warning statement is applicable)

2VAA001695 1
 Safety Precaution Description
SPECIFIC CAUTIONS Remove a module from its assigned slot before installing
or removing a cable assigned to that slot. Failure to do so
could result in damage to the module. Refer to sub-
sections 2.5.2.1- NKTU01 and NKTU11 and 4.3-
Termination Unit Replacement of this user manual, where
this specific caution statement is applicable).

2 2VAA001695
About This Book

About This Book

Document Conventions
Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key
sequences, prompts, messages, menu items, screen elements, etc.

Information and Tip Icons

This publication includes Information and Notes where appropriate to point out important information or useful hints to the
reader. The corresponding sections should be interpreted as follows:
Information alerts the reader to pertinent facts and conditions

Warning indicates the presence of a hazard which could result in a plant shutdown.:

Caution indicates the presence of a hazard which could result in personal or hardware
module damage.

NOTE Note indicates advice on, for example, how to design your project or how to use a certain function

2VAA001695 3
 About This Book

4 2VAA001695
1. Introduction Overview

1. Introduction
1.1 Overview
The NTCS04 Controller/Station Termination Unit is a Harmony rack I/O device that is part of the Symphony Enterprise
Management and Control System. It provides connections for a Harmony controller, IMCIS12 Control I/O or IMQRS12
Quick Response module, and IISAC01 Analog Control Stations. Serial link connections for daisy-chaining additional
NTCS04 termination units are also provided.

The following figure (Figure 1-1) shows the Harmony rack I/O architecture. A Harmony area controller and the Harmony
rack controllers can use the rack I/O module and termination units for I/O interface.

Figure 1-1 Harmony Rack I/O Architecture

1.2 Mounting Hardware

Harmony termination units mount in standard ABB Automation enclosures (CAB-01, CAB-04, CAB-12). An NFTP01 Field
Termination Panel is used for termination unit mounting (Figure 1-2). The panel attaches to the side rails in standard 438-
millimeter (19-inch) enclosures.

Figure 1-2 Mounting Hardware

2VAA001695 1-1
Intended User 1. Introduction

1.3 Intended User

Personnel installing, operating, or maintaining the NTCS04 termination unit should read this user manual before performing
any installation, operation, or maintenance procedures. Installation requires an engineer or technician with experience in
handling electronic circuitry. Personnel working with the NTCS04 termination unit should have experience working on it and
know the precautions to take around AC/DC power. Knowledge of the Symphony system and electronic principles is also
mandatory.

1.4 User Manual Content

The user manual consists of the following sections:

• Introduction
This section provides an overview of the NTCS04 termination unit.

• Installation:
This section explains the physical installation, wiring and cable requirements, dipshunt settings and handling of
the termination unit.

• Maintenance:
This section describes the maintenance schedule.

• Repair and Replacement:

This section explains how to replace the fuses and termination unit.

1.5 How to use this Manual

Make sure to read this user manual in sequence. It is important to become familiar with the entire contents of the user
manual before using the module.

This user manual is organized to enable quick information retrieval:

1. Perform the steps in the Installation section.
2. Refer to the Maintenance section for scheduled maintenance requirements.
3. Refer to the Repair and Replacement section to replace a termination unit.

1.6 Document Conventions

The ‘?’ in the nomenclature or in a part number indicates a variable for that position (e.g., IMMFP1?).

1.7 Reference Documents

The following table (Table 1-1) lists ABB Automation instructions for equipment that is referenced in this user manual.

Table 1-1 Reference Documents

Number Document

WBPEEUI200502?? Module Mounting Unit (IEMMU11, IEMMU12,

IEMMU21, IEMMU22)

WBPEEUI200505?? Site Planning Guidelines

WBPEEUI230022?? IISAC01 Analog Control Station

2VAA001810 Control I/O Module and Quick Response I/O Module

(SPCIS22/SPQRS22)

1-2 2VAA001695
1. Introduction Related Nomenclature

1.8 Related Nomenclature

The following table (Table 1-2) lists the nomenclature related to the NTCS04 termination unit.

Table 1-2 Related Nomenclature

Nomenclature Description

IEMMU11, EMMU12, Module mounting unit

IEMMU21, IEMMU22

CIS12 Control I/O module

QRS12 Quick response module

NFTP01 Field termination panel

NKCS01 Termination unit to IISAC01 station cable (PVC)

NKCS02 Termination unit to first of multiple IISAC01

stations cable (PVC)

NKCS11 Termination unit to IISAC01 station cable (non-

PVC)

NKCS12 Termination unit to first of multiple IISAC01

stations cable (non-PVC)

NKDS03 IISAC01 station interconnection cable (PVC)

NKDS13 IISAC01 station interconnection cable (non-PVC)

NKSE01 Termination unit interconnection cable (PVC)

NKSE11 Termination unit interconnection cable (non-PVC)

NKTU01 Termination unit to module cable (PVC)

NKTU11 Termination unit to module cable (non-PVC)

1.9 Specifications
The following table (Table 1-3) lists the NTCS04 termination unit specifications.

Table 1-3 NTCS04 Termination Unit Specifications

Property Characteristic/Value

Inputs
4 Analog 4 to 20 mA
3 Digital 24 VDC
125 VDC

Outputs
2 Analog 1 to 5 VDC
4 to 20 mA
4 Digital 24 VDC at 250 mA (isolated, open-collector type)

Cable insulation
PVC (UL rating PLTC) 80°C (176°F) at 300 V
Non-PVC (UL rating PLTC) 90°C (194°F) at 300 V

Mounting Mounts on the field termination panel.

Surge Protection Meets IEEE-472-1974 Surge Withstand Capability Test

2VAA001695 1-3
Specifications 1. Introduction

Table 1-3 NTCS04 Termination Unit Specifications (Continued)

Property Characteristic/Value

Environmental
Ambient temperature 0° to 70°C (32° to 158°F)
Relative humidity 5% to 95% up to 55°C (131°F) (noncondensing)
5% to 45% at 70°C (158°F) (noncondensing)
Pollution degree: I
Altitude Sea level to 3 km (1.86 mi)
Air quality Noncorrosive

Cooing requirements No cooling is required when used in ABB Automation cabinets

and operated within environmental limits.

Installation category III

Certifications
Canadian Standards
Association (CSA)
Factory Mutual (FM)
Certified for use as process control equipment in an ordinary
(nonhazardous) location.
Approval as nonincendive equipment for use in Class I; Division
2; Groups A,B,C,D; hazardous locations.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

1-4 2VAA001695
2. Installation Introduction

2. Installation
2.1 Introduction
This section explains what must be done before putting the NTCS04 termination unit into operation. Do not proceed with
operation until the steps are read, understood and executed in the order in which they appear.

2.2 Special Handling

Observe the following steps when handling electronic circuitry:
1. Use Static Shielding Bag: Keep an assembly in its static shielding bag until ready to install it in the system.
Save the bag for future use.
2. Ground Bags before Opening: Before opening a bag containing an assembly with static sensitive devices,
touch it to the equipment housing or ground to equalize charges.
3. Avoid Touching Circuitry: Handle assemblies by the edges; avoid touching the circuitry.
4. Avoid Partial Connection of Semiconductors: Verify that all devices connected to the module are properly
grounded before using them.
5. Ground Test Equipment.
6. Use an Antistatic Field Service Vacuum: Remove dust from assemblies if necessary.
7. Use a Grounded Wrist Strap: Use the ABB Automation field static kit (part number 1948385A1 - consisting of
two wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with
modules. The kit grounds a technician and the static dissipative work surface to the same ground point to
prevent damage to the circuitry by electrostatic discharge. Connect the wrist strap to the appropriate grounding
plug on the power supply or to an unpainted portion of the enclosure with the alligator clip. The wrist strap must
be effectively connected to the earth grounding electrode system through the AC safety ground.
8. Do Not Use Lead Pencils to Set Switches: To avoid contamination of switch contacts that can result in
unnecessary circuit board malfunction, do not use a lead pencil to set a switch.

2.3 Unpacking and Inspection

Follow the given steps to unpack and inspect the termination unit:
1. Examine the hardware immediately to verify it has not been damaged in transit.
2. Notify the nearest ABB sales office of any such damage.
3. File a claim for any damage with the transportation company that handled the shipment.
4. Use the original packing material and container to store the hardware.
5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes.

2.4 Setup/Physical Installation

Set the dipshunts, install the fuses, and install the relays before installing or operating the NTCS04 termination unit.
Figure 2-1 shows the layout of the termination unit.

2.4.1 Dipshunt Configuration

There are nine dipshunts on the termination unit. Figure 2-1 shows the locations of the dipshunts. Dipshunts XU01 and
XU02 determine the I/O module relay control. Configure a dipshunt by either cutting straps or leaving straps uncut in certain
sequences. Cut the dipshunt straps using a standard shunt cutting tool. Always cut straps completely. Install the configured
dipshunt into the desired socket on the termination unit. To install a dipshunt, align the end of the dipshunt identified with the
silver dot to the end of the socket having an identification mark and push the dipshunt into the socket. Be careful not to bend

2VAA001695 2-1
Dipshunt Configuration 2. Installation

any pins during insertion. Table 2-1, Table 2-2, Table 2-3, and Table 2-4 details the dipshunt configurations that are
applicable for each socket location.

Figure 2-1 Termination Unit Layout

Table 2-1 Analog Input

Application/Signal Type Dipshunt Configuration XU1 - XU4

System powered
4 - 20 mA

Externally powered
4 - 20 mA

2-2 2VAA001695
2. Installation Dipshunt Configuration

Table 2-1 Analog Input (Continued)

Application/Signal Type Dipshunt Configuration XU1 - XU4

Single ended voltage

Differential voltage

Table 2-2 Digital Input

Application/Signal Type Dipshunt Configuration XU5 - XU7

System powered
E3/E4

Field powered1

NOTE: Using the field device to complete the path to ground is commonly
referred to as switching neutral. Using the field device to complete the path
to the I/O module is referred to as switching hot. If switching hot is the
desired method, the field powered dipshunt configuration must be used. If
system power is required, it should be wired as a field source. Refer to
Figure 2-2 for an example of switching hot and switching neutral.

Table 2-3 Analog Input (with Station Feedback)

Application/Signal Type Dipshunt Configuration XU8

Station No. 1
(P2 connector)

Station No. 2
(P3 connector)

2VAA001695 2-3
Fuse Installation 2. Installation

Table 2-4 Analog Output

Application/Signal Type Dipshunt Configuration XU9

Both outputs in voltage mode

Output 1 in voltage mode,

Output 2 in current mode

Output 1 in current mode,

Output 2 in voltage mode

Both outputs in current mode

(no dipshunt required)

Figure 2-2 Switching Hot vs Switching Neutral

2.4.2 Fuse Installation

ABB Automation ships a 0.25 amp/250 volt fuse (ABB Automation P/N 1948182A32500), a 2.0 amp/250 volt fuse (ABB
Automation P/N 1948182A32001) and two 4.0 amp/125 volt fuses (ABB Automation P/N 1948182A34001) with every
NTCS04 termination unit.

Follow the given steps to install the fuses:

1. Install a 4.0 A fuse into fuse clip F1 and F3 (Figure 2-1).
2. Install the 2.0 A fuse into fuse clip F2.
3. Install the 0.25 A fuse into fuse clip F4.

2.5 Termination Unit Installation

The termination unit is ready for installation when the dipshunts are properly installed and configured, and the relays and
fuses are in place. The termination unit mounts on a standard NFTP01 field termination panel as shown in Figure 1-2.

2-4 2VAA001695
2. Installation Mounting

2.5.1 Mounting
Follow the given steps to mount the NTCS04 termination unit to the field termination panel:
1. Remove the safety shield.
2. Insert the tabs of the circuit board into the proper slots of the termination panel standoff as shown in Figure 2-3
and slide the circuit board into position.

Figure 2-3 Termination Unit Installation

3. Secure the termination unit circuit board to the field termination panel with two No. 10 self-tapping screws.
4. Install a No. 10 self-tapping screw for the chassis common connection (Figure 2-4).

Figure 2-4 Chassis Common Connection

2VAA001695 2-5
Termination Unit Cables 2. Installation

2.5.2 Termination Unit Cables

After mounting the termination unit to the field termination panel, install the termination cables.

Figure 2-5 and Figure 2-6 show how to connect cables to the NTCS04 termination unit.

Figure 2-5 Controller to IISAC01 Station Cable Connections

2.5.2.1 NKTU01 and NKTU11

Follow the given steps to connect the NTCS04 termination unit to an I/O module::
Remove a module from its assigned slot before installing or removing a cable assigned to
that slot. Failure to do so could result in damage to the module.

2-6 2VAA001695
2. Installation Termination Unit Cables

1. Install the J2 connector of the NKTU01 or NKTU11 termination unit cable in the module mounting unit backplane
slot assigned to the I/O module.

Figure 2-6 Controller to I/O Module Cable Connections

2. Insert the J1 connector of the NKTU01 or NKTU11 termination unit cable into P1 of the termination unit.

2.5.2.2 NKSE01 and NKSE11

This cable extends the rack controller serial link from a NTMP01 termination unit to a NTCS04 termination unit. It also
extends the serial link from one NTCS04 termination unit (with or without stations) to another.

Follow the given steps to install the serial extension cable:

1. Insert one end of the cable into the P3/P4 connector of the NTMP01 termination unit or the P4/P5 connector of
the NTCS04 termination unit (NTCS04 to NTCS04 application).

NOTE: The cable should latch securely in place.

2. Insert the other end of the cable into the P4/P5 connector of the NTCS04 termination unit.

NOTE: The cable should latch securely into place.

2.5.2.3 NKCS01, NKCS02, NKCS11, and NKCS12

The NKCS01 and NKCS11 cables connect the NTCS04 termination unit to a single IISAC01 station. The NKCS02 and
NKCS12 cables connect the first of multiple IISAC01 stations to the termination unit.

Follow the given steps to install the station cable:

1. Remove the IISAC01 station from the station housing.
2. Insert the hooded end into the station housing backplane. The cable inserts into the right slot of the station
housing backplane.

NOTE: The cable should latch securely into place. Card edge connector P1 of the station circuit board con-
nects to this end of the cable.

3. Insert the male 24 pin connector end of the cable into the P2/P3 connector of the NTCS04 termination unit.

NOTE: The cable should latch securely into place.

4. Reinstall the IISAC01 station into the station housing.

2.5.2.4 NKDS03 and NKDS13

This cable interconnects multiple IISAC01 stations.

2VAA001695 2-7
Power Wiring 2. Installation

Follow the given steps to install the cable:

1. Remove the IISAC01 station from the station housing.
2. Insert the hooded end of the cable into the station housing backplane. The cable inserts into the right slot of the
station housing backplane.

NOTE: The cable should latch securely into place. Card edge connector P1 of the station circuit board con-
nects to this end of the cable.

3. Insert the male six pin connector end of the cable into the female six pin connector end of the NKCS02 or
NKCS12 cable when connecting the second of multiple stations.
4. Insert the connector end of the cable into female six pin connector end of the NKDS03 cable when connecting
three or more stations.

NOTE: The cable should latch securely into place.

5. Reinstall the IISAC01 station into the station housing.

2.5.3 Power Wiring

There are four terminals that provide power and ground connections. Refer to Figure 2-1 for terminal locations. Terminal E1
is the +24 VDC power connection. Terminals E2 and E4 are I/O common grounds. Terminal E3 is for +24 VDC or +125 VDC
digital input power. The power source connected to terminal E3 depends on the digital input logic, signal level required. A
chassis ground point is on the edge of the circuit board next to the P1 plug. This will connect the NTCS04 termination unit to
the chassis ground point of the NFTP01 Field Termination Panel.

Follow the given steps to connect the power wiring:

Verify the main power, field power, and power entry panel circuit breakers/switches are
turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do
so could result in severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete.
1. Attach a 14 AWG wire from the +24 VDC power distribution source to the E1 terminal on the termination unit.
2. Attach one 14 AWG wire from the I/O common to the E2 terminal of the termination unit.
3. Attach a 14 AWG wire from the I/O common to the E4 terminal of the termination unit.
4. Attach a 14 AWG wire from the +24 VDC power distribution source or the +125 VDC auxiliary power distribution
source to the E3 terminal of the termination unit.

Refer to the Modular Power System instruction for further details.

2.5.4 Terminal Block Wiring

Refer to Figure 2-7 for terminal block assignments and terminal polarity. Field wiring should be 12 to 22 AWG wire. Digital
I/O lines should be twisted pairs of multistranded wire with low leakage insulation. The input lines should be shielded,
although it is generally not necessary for each pair of wires to be separately shielded. The shields should be grounded to
the chassis common. The twisted pairs of input lines must not be in the same conduit with lines carrying either AC voltages
or switched outputs (such as those from digital output relays) greater than 50 volt-amps DC. Terminals TB3-1 and TB3-2 are

2-8 2VAA001695
2. Installation Connector Pinouts

auxiliary +24 VDC power connections. They can be connected to digital output terminals only and are fused. Proper wiring
polarity is required for DC voltage signals.

Figure 2-7 Terminal Assignments

2.6 Connector Pinouts

Refer to Table 2-5 for P1 pinout connections, Table 2-6 for P2 and P3 pinout connections, and Table 2-7 for P4/P5 pinout
connections.

Table 2-5 P1 Pinout Connections

Pin Signal Pin Signal Pin Signal

1 DO1- 7 DO4- 13 SL-

2 DO1+ 8 DO4+ 14 SHIELDS
3 DO2- 9 NC 15 NC
4 DO2+ 10 NC 16 SL+
5 DO3- 11 NC 17 DI1-
6 DO3+ 12 NC 18 DI1+

19 DI2- 25 AO1- 31 AI2-

20 DI2+ 26 AO1+ 32 AI2+
21 DI3- 27 AO2- 33 AI3-
22 DI3+ 28 AO2+ 34 AI3+
23 +24 VDC 29 AI1- 35 AI4-
24 COM 30 AI1+ 36 AI4+
NOTE: DO=Digital Output, DI=Digital Input, AI=Analog Input, AO=Analog
Output, SL=Serial Link, NC=Not Connected

2VAA001695 2-9
I/O Signal Connections 2. Installation

Table 2-6 P2/P3 Pinout Connections

Pin Signal Pin Signal

1 Serial link (-) 13 M/A common

2 Serial link (+) 14 M/A select
3 +24 VDC 15 R/L common
4 Supply common 16 Raise
5 M/A power 17 R/L common
6 M/A common 18 Lower
7 Analog output (-)1 19 Analog input (-)3
8 Analog output (+)1 20 Analog input (+)3
9 Analog load (-) 21 NC
10 Analog load (+) 22 NC
11 Analog input (-)2 23 NC
12 Analog input (+)2 24 Cable shield
NOTES:
1. Connected to analog output 1 for P2, analog output 2 for P3.
2. Connected to analog input 3 for P2, analog input 4 for P3.
3. Connected to analog input 1 for P2, analog input 2 for P3.

Table 2-7 P4/P5 Pinout Connections

Pin Signal Pin Signal

1 Serial link (-) 4 NC

2 Serial link (+) 5 NC
3 NC 6 Chassis common
NOTE: NC = Not connected

2.7 I/O Signal Connections

Table 2-8 shows the cable pin connections from the P3 connection of an I/O module to the P1 connection of the NTCS04
termination unit.

Table 2-8 I/O Signal Connections

NKTU01 and NKTU11

P31 P12 P31 P12

1 ––––––––– 1 J ––––––––– 22

A ––––––––– 2 9 ––––––––– 23

2 ––––––––– 3 K ––––––––– 24

B ––––––––– 4 10 ––––––––– 25

3 ––––––––– 5 L ––––––––– 26

C ––––––––– 6 11 ––––––––– 27

4 ––––––––– 7 M ––––––––– 28

D ––––––––– 8 12 ––––––––– 29

5 ––––––––– 13 N ––––––––– 30

E ––––––––– 16 13 ––––––––– 31

6 ––––––––– 17 P ––––––––– 32

F ––––––––– 18 14 ––––––––– 33

2-10 2VAA001695
2. Installation Installation Complete

Table 2-8 I/O Signal Connections (Continued)

NKTU01 and NKTU11

P31 P12 P31 P12

7 ––––––––– 19 R ––––––––– 34

H ––––––––– 20 15 ––––––––– 35

8 ––––––––– 21 S ––––––––– 36
NOTES:
1. P3 on I/O or controller module (letters on
component side of circuit board, numbers on
solder side of circuit board).
2. P1 on NTCS04.

2.8 Installation Complete

The termination unit is ready for operation when:
• Dipshunts or plug adapters are installed.
• Fuses are installed.
• Termination unit is installed on field termination panel.
• The cables are connected.
• Power wiring is connected and applied to termination unit.
• Terminal block wiring is connected to termination unit and field device.
• Safety shield is installed.

2VAA001695 2-11
Installation Complete 2. Installation

2-12 2VAA001695
3. Maintenance Introduction

3. Maintenance
3.1 Introduction
The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB
Automation recommends that all equipment receive preventive maintenance which will keep the equipment operating at an
optimum level.

This section presents procedures that the customer should be able to perform on site. These preventive maintenance
procedures should be used as a guideline to assist in establishing good preventive maintenance practices.

Personnel performing preventive maintenance should meet the following qualifications.

• Should be qualified electrical technicians or engineers that know the proper use of test equipment.
• Should be familiar with the module mounting unit and field termination panel,
• Have experience working with process control systems,
• Know what precautions to take when working on live AC and/or DC systems.

3.2 Preventive Maintenance Schedule

The following table (Table 3-1) details the preventive maintenance schedule for the NTCS04 termination unit. The table lists
the preventive maintenance tasks in groups according to their specified maintenance interval. Tasks that require further
explanation are covered under sub-section 3.4- Preventive Maintenance Procedures of this user manual.
NOTE: The preventive maintenance schedule is for general purposes only. Your application may require special
attention.

Table 3-1 Preventive Maintenance Schedule

Task Frequency

Check cabinet air filters. Clean or replace them as necessary. Check the air filter 3 months
more frequently in excessively dirty environments.

Check cabinet and termination unit for dust. Clean as necessary using an antistatic
vacuum.

Check all termination unit signal, power and ground connections within the cabinet.
Verify that they are secure. Refer to procedure.

Check termination unit circuit board, giving special attention to power contacts and 12 months
edge connectors. Clean as necessary. Refer to procedure.

Complete all tasks in this table. Shutdown

3.3 Equipment and Tools Required

Tools and equipment required for maintenance procedures are:
• Antistatic vacuum.
• Screwdriver (medium length).
• Isopropyl alcohol (99.5 percent electronic grade).
• Distilled water.
• Compressed air.
• Foam-tipped swabs.
• Lint-free cloths.
• Nonabrasive eraser.

3.4 Preventive Maintenance Procedures

This section covers tasks from Table 3-1 that require specific instructions or further explanation.
• Cleaning printed circuit boards and edge connectors.

2VAA001695 3-1
Printed Circuit Board Cleaning 3. Maintenance

• Checking signal, power and ground connections.

3.4.1 Printed Circuit Board Cleaning

Never clean electrical parts or components with live power present. Doing so exposes you
to an electrical shock hazard.

Wear eye protection whenever working with cleaning solvents. When removing solvents
from printed circuit boards using compressed air, injury to the eyes could result from
splashing solvent as it is removed from the printed circuit board.
There are several circuit board cleaning procedures in this section. These procedures cover circuit board cleaning and
washing, cleaning edge connectors and circuit board laminate between edge connectors. Use the procedures that meet the
needs of each circuit board. Remove all dust, dirt, oil, corrosion or any other contaminant from the circuit board.
Perform all cleaning and handling of the printed circuit boards at static safe work stations. Always observe the steps
under sub-section 2.2- Special Handling of this user manual when handling printed circuit boards.

3.4.1.1 General Cleaning and Washing

If the printed circuit board needs minor cleaning, remove dust and residue from the printed circuit board surface using
clean, dry, filtered compressed air or an antistatic field service vacuum cleaner.

Follow the given steps to wash the printed circuit board:

1. Clean the printed circuit board by spraying or wiping it with isopropyl alcohol (99.5% electronic grade).

NOTE: Use a foam-tipped swab to wipe the circuit board.

2. Remove excess solvent by using compressed air to blow it free of the circuit board.

3.4.1.2 Edge Connector Cleaning

Follow the given steps to clean the edge connector:

1. Use a solvent mixture of 80% isopropyl alcohol (99.5% electronic grade) and 20% distilled water.
2. Soak a lint-free cloth with the solvent mixture.
3. Work the cloth back and forth parallel to the edge connector contacts.
4. Repeat with a clean cloth that is soaked with the solvent mixture.
5. Dry the edge connector contact area by wiping with a clean lint-free cloth.

Follow the given steps to clean tarnished or deeply stained edge connector contacts:
1. Use a nonabrasive eraser or equivalent to remove tarnish or stains.

NOTE: Fiberglass or nylon burnishing brushes may also be used.

2. Minimize electrostatic discharge by using the 80/20 isopropyl alcohol/water solution during burnishing.

NOTE: Do not use excessive force while burnishing. Use only enough force to shine the contact surface.

3. Inspect the edge connector after cleaning to assure no loss of contact surface.
4. Wipe clean with a lint-free cloth.

3.4.2 Checking Connections

NOTE: Power to the cabinet should be off while performing this preventive maintenance task.
There are exposed AC and DC connections inside the cabinet. These exposed electrical
connections present a shock hazard that can cause injury or death.

If input or output circuits are a shock hazard after disconnecting system power at the
power entry panel, then the door of the cabinet containing these externally powered
circuits must be marked with a warning stating that multiple power sources exist.

Check all signal wiring, power and ground connections within the cabinet to verify their integrity. When checking
connections, always turn a screw, nut or other fastening device in the direction to tighten only. If the connection is loose, it

3-2 2VAA001695
3. Maintenance Checking Connections

will be tightened. If the connection is tight, the tightening action will verify that it is secure. There must not be any motion
done to loosen the connection.

NOTES:
1.Verify that all power connections within the cabinet are secure.

2.Verify that all wiring connections to the termination unit are secure.

2VAA001695 3-3
Checking Connections 3. Maintenance

3-4 2VAA001695
4. Repair and Replacement Introduction

4. Repair and Replacement

4.1 Introduction
This section explains the repair and replacement procedures for an NTCS04 termination unit.

4.2 Fuse Replacement

If a fuse opens, replace it with a fuse having an equivalent rating.

Table 4-1 describes the fuses and lists their ABB Automation part numbers.

Follow the given steps to replace a fuse:

1. Turn off power to the cabinet.
2. Remove the safety shield.
3. Remove the blown fuse from its holder.
4. Replace the blown fuse with an equivalent fuse.
5. Install the safety shield.
6. Turn on power to the cabinet.

Table 4-1 Parts List

Part Number Description

194818234001 Fuse, 4.0 A, 125 V

1948182A32001 Fuse, 2.0 A, 250 V

1948182A32500 Fuse, 0.25 A, 250 V

NFWAB17010 0.19-16 (no. 10) x 5/8 in. Phillips-head thread forming

screw

NTLAC19000 0.19 in. (no. 10) external tooth lock washer

4.3 Termination Unit Replacement

If it is determined that the termination unit is faulty, replace it with a new one. Do not try to repair the unit; replacing
components may affect the unit performance and certification. When replacing a termination unit, observe the special
handling guidelines listed in section 2- Installation of this user manual.

NOTE: Turn off power to the field devices before removing the cables from the termination unit.
Remove a module from its assigned slot before installing or removing a cable assigned to
that slot. Failure to do so could result in damage to the module.

Follow the given steps to replace the termination unit:

1. Turn off power to the cabinet and remove the safety shield.
2. Disconnect the power and I/O common wiring from the E1, E2, E3, and E4 Faston connectors of the termination
unit.
3. Mark the wires according to their terminal assignment as they are removed.
4. Disconnect all termination unit cables and mark them according to their connector assignment as they are
removed.
5. Turn off power to the field devices.
6. Disconnect I/O wiring from the terminal blocks.
7. Mark the wires according to their terminal assignment as they are removed.
8. Remove the two mounting screws (and one chassis common screw), when all cables and wires are removed
from the termination unit,
9. Remove the termination unit from the field termination panel.
10. Verify that the dipshunts (and if plug adapters are used) on the replacement termination unit are the same as the
dipshunt settings on the faulty termination unit.

2VAA001695 4-1
Termination Unit Replacement 4. Repair and Replacement

11. Verify that the fuses (F1 - F4) are installed on the replacement termination unit.
12. Secure the replacement termination unit circuit board to the field termination panel with the two mounting
screws.
13. Connect the termination unit cables to their assigned connector on the termination unit.
14. Connect the I/O wiring to the terminal blocks.
15. Connect the power and I/O common wiring to the E1, E2, E3, and E4 Faston connectors of the termination unit.
16. Push on the faceplate of the I/O module to fully insert it into its module mounting unit slot.

NOTE: The I/O modules should be seated in the termination unit cable at the rear of the module mounting unit
when fully inserted.

17. Install the safety shield and return power to the field devices, after all cables and wiring are replaced.
18. Return power to the cabinet.

4-2 2VAA001695
 INDEX

C
Checking connections 2
Cleaning
Edge connectors 2
Printed circuit boards 2
Conventions, documents 2
F
Field static kit 1
Fuse
Installation 4
Replacement 1
H
How to use this instruction 2
I
I/O wiring 8
Installation
Cables 6
Fuse 4
Termination unit 4
M
Maintenance 1
Schedule 1
Tools required 1
Mounting hardware 1
N
Nomenclature 3
O
Overview 1
P
Parts list 1
PCB cleaning 2
Preventive maintenance
Checking connections 2
Schedule 1
Tools and equipment 1
R
Replacement
Fuse 1
Termination unit 1
S
Setup/physical installation 1
Special handling 1
T
Termination unit
Cables 6
Dipshunt configuration 1
Installation 4
Mounting 5
Replacement 1
U
Unpacking and inspection 1
User qualifications 2

2VAA001695 1
INDEX

2 2VAA001695
ABB Ltd.
Business Unit Power Generation
P.O. BOX 8131
8050 Zürich
SWITZERLAND
Phone: +41 (0) 43 317-5380
Fax: +41 (0) 43 317-5382
www.abb.com/powergeneration
Notice
Document Number: 2VAA001695
The information in this document is subject to change
without notice and should not be construed as a com-
mitment by ABB. ABB assumes no responsibility for
any errors that may appear in this document.
In no event shall ABB be liable for direct, indirect, spe-
cial, incidental or consequential damages of any nature
or kind arising from the use of this document, nor shall
ABB be liable for incidental or consequential damages
arising from use of any software or hardware described
in this document.
This document and parts thereof must not be repro-
duced or copied without written permission from ABB,
and the contents thereof must not be imparted to a third
party nor used for any unauthorized purpose.
The software or hardware described in this document is
furnished under a license and may be used, copied, or
disclosed only in accordance with the terms of such
license.
This product meets the requirements specified in EMC
Directive 2004/108/EC and in Low Voltage Directive
2006/95/EC.
Copyright © 2011-2012 by ABB.
All rights reserved.
Release: June 2012