Model PDP DPU Installa Install ation ti on,, Preparatio reparation n and Adjustme Adjus tment nt 277573 Rev. A1
Refer to this publication for complete and accurate information that helps you better operate and service Metso Automation MAX Controls equipment. Yo ur comments and suggestions are welcome. Metso Automation MAX Controls 1180 Church Road Lansdale, PA 19446 Attention: Manager, Technical Publications
Copyright 1999-2001 by Metso Automation MAX Controls Inc. Printed in the United States of America All rights reserved
Metso Metso Autom ation MAX Controls • 277573
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Refer to this publication for complete and accurate information that helps you better operate and service Metso Automation MAX Controls equipment. Yo ur comments and suggestions are welcome. Metso Automation MAX Controls 1180 Church Road Lansdale, PA 19446 Attention: Manager, Technical Publications
Copyright 1999-2001 by Metso Automation MAX Controls Inc. Printed in the United States of America All rights reserved
Metso Metso Autom ation MAX Controls • 277573
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Contents PREFACE ..................................................... ................................................................................ ...................................................... .......................................... ................. III CHAPTER 1 ................................................ ......................................................................... ................................................... ............................................. ................... 1-1 Introduction........... Introduction......................... ............................ ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ......................... ........... 1-1 Distributed Distributed Processing Processing Unit Functionalit Functionality y ......................... ...................................... .......................... ......................... ......................... .......................... ............................ ....................... ........ 1-1 Distributed Distributed Processing Processing Unit Hardware........................ Hardware...................................... ........................... ........................... ............................ ........................... ............................ .................. ... 1-1 Distributed Distributed Processing Processing Unit Specification Specificationss ......................... ...................................... ........................... ........................... .......................... ........................... ......................... ........... 1-2 Mounting Mounting the DPU ........................... ........................................ ........................... ........................... ........................... ........................... ........................... .............................. .............................. .................... ...... 1-2 Positioning Positioning the DPU............................. DPU........................................... ........................... ........................... ........................... ........................... ............................ ............................ ........................... ............. 1-2 Mounting Mounting Procedures Procedures ............................ ......................................... ........................... ............................ ............................ ............................ ............................ ............................. ......................... .......... 1-3 Wiring the DPU .......................... ........................................ ........................... ........................... ............................ ............................ ........................... ............................ .............................. ......................... .......... 1-3
CHAPTER 2 ................................................ ......................................................................... ................................................... ............................................. ................... 2-1 DPU Front Panel...................................... Panel................................................... ........................... ............................ ........................... ........................... ............................. ............................. ............................. .................. ... 2-1 Overview................... Overview................................. ............................ ........................... ........................... ............................ ............................ ........................... ............................. .............................. ............................. .................. ... 2-1 Mode Select DIP Switch Switch Settings......... Settings...................... .......................... .......................... .......................... ........................... ........................... ........................... ............................ .................... ...... 2-1 Data Highway Highway Area................................... Area................................................. ........................... ........................... ........................... ........................... ............................. .............................. ......................... .......... 2-2 Using Rotary Switches to Set Station Address........... Address ........... ........... ............ ........... ........... ........... ............ ......... .......... 2-2 Two LED Displays................ Displays.............................. ............................ ........................... ........................... ............................ ........................... ............................ ............................. ........................... ............. 2-3 IOM Load.................... Load.................................. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ...................... ........ 2-3 Status Section Section (LEDs)..................................... (LEDs)................................................... ........................... ........................... ........................... ........................... ............................ ............................. .................... ..... 2-4 DPU Hardware Hardware Status LEDs ........................... ......................................... ........................... ........................... ........................... ........................... ............................. ............................. ................ 2-4 Serial I/O and DPU Status Section..................... Section.................................. .......................... ........................... ........................... .......................... ........................... ............................ ................ 2-4 Backup Backup Status LEDs................. LEDs............................... ............................ ........................... ........................... ............................ ........................... ........................... ............................. ......................... .......... 2-5 Reset Button.............................. Button........................................... ........................... ............................ ............................ ............................ ............................ ............................ ............................ ........................... ............. 2-6 Backup Backup Link................................. Link............................................... ............................ ............................ ............................ ............................ ............................ ............................. ............................. ...................... ........ 2-6 CPU Load................... Load................................. ............................ ........................... ........................... ............................ ........................... ........................... .............................. .............................. ........................... ............. 2-6 Takeover Takeover Button..................... Button................................... ............................ ............................ ............................ ............................ ............................. ........................... ........................... ............................. ................ 2-6 Backup Backup DIP Switch Settings Settings ......................... ....................................... ........................... .......................... ........................... ........................... ............................ ............................. ...................... ........ 2-6 DPU Keyswitch....... Keyswitch..................... ........................... ........................... ........................... ........................... ........................... ........................... ............................. .............................. ............................. ................. ... 2-7
CHAPTER 3 ................................................ ......................................................................... ................................................... ............................................. ................... 3-1 Input/Output Input/Output Connections...... Connections................... .......................... ......................... ......................... .......................... .......................... .......................... ............................ ............................. ........................... ............. 3-1 Data Highway....... Highway..................... ............................ ........................... ........................... ............................ ........................... ........................... ............................ ............................ ............................ ......................... ........... 3-1 ACSII Ports...................................... Ports.................................................... ............................ ............................ ............................ ............................ ........................... ............................ ............................. ................ 3-1
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Model Model PDP PDP DPU DPU Installati Inst allation, on, Preparation and Adjust Adj ustment ment
CHAPTER 4...................................................... 4............................................................................... ................................................... ........................................4-1 ..............4-1 DPU Battery and Fuse Maintenance Maintenance .......................... ....................................... ........................... ........................... ........................... ........................... ............................ ............................ ............. 4-1 Battery Types ........................... ......................................... ........................... ........................... ............................ ............................ ............................ ............................ ............................ ............................. .................. ... 4-1 Replacing the NiCd Battery Pack (Battery #2)........ .......... ........... ........... ........... ........... .......... ........... .......... ......... 4-1 Replacing Replacing the Lithium Lithium Battery (Battery #1) ......................... ....................................... ........................... ........................... ........................... ........................... ........................... ............. 4-2 Replacing Replacing DPU Fuses............... Fuses............................ .......................... ........................... ........................... ........................... ........................... ............................ .............................. ............................. ................ 4-3
CHAPTER 5...................................................... 5............................................................................... ................................................... ........................................5-1 ..............5-1 Backing Backing up the DPU................................. DPU............................................... ........................... ........................... ........................... .......................... ............................. .............................. ............................ .................. .... 5-1 Overview Overview .......................... ........................................ ............................ ........................... ........................... ............................ ........................... ............................. .............................. ............................ ......................... ........... 5-1 Automatic Automatic Failover/Manu Failover/Manual al Takeover................. Takeover............................... ........................... ........................... ........................... ........................... ........................... .......................... ............. 5-1 Automatic Automatic Failover........................ Failover...................................... ........................... ........................... ........................... ........................... ........................... ............................ ............................. .................... ...... 5-1 Manual Manual Takeover............ Takeover.......................... ........................... ........................... ............................ ............................ ............................ ............................ ............................ ............................ .................... ...... 5-1 Cable Disconnect....... Disconnect..................... ............................ ........................... ........................... ............................ ............................ ........................... ............................ .............................. ......................... .......... 5-2
CHAPTER 6...................................................... 6............................................................................... ................................................... ........................................6-1 ..............6-1 Starting the DPU ........................... ......................................... ........................... ........................... ............................ ........................... ........................... ............................. ............................. ............................ ................ 6-1 Startup States................... States................................ ........................... ........................... ........................... ........................... ........................... ........................... ............................ ............................. ............................ ................ 6-1 Demanding Demanding a Cold Startup .......................... ....................................... ........................... ........................... ........................... ........................... ........................... ............................. ......................... .......... 6-2 Starting Starting a Standalone Standalone DPU................................. DPU.............................................. .......................... .......................... ........................... ........................... ............................ .............................. .................. ... 6-2 Starting Starting a Backup Backup Pair of DPUs .......................... ........................................ ........................... ........................... ........................... ........................... ............................. ............................. ................ 6-3 Replacing Replacing a DPU in a Backup Backup Pair.................... Pair................................. ........................... ........................... ........................... ........................... ............................ .............................. .................. ... 6-5
CHAPTER 7..................................................... 7............................................................................... ................................................... .......................................7-1 ..............7-1 Using Interaction Interaction Pages ............................ ......................................... ........................... ............................ ........................... ........................... ............................. .............................. ............................. ................ 7-1 Accessing Accessing Displays............. Displays........................... ............................ ........................... ........................... ............................ ............................ ........................... ........................... ............................ ......................... ........... 7-1 Using Interaction Page 9 Display with a Workstation .......... ........... ........... ........... ........... ........... ........... .......... ..... 7-1 Startup .......................... ........................................ ............................ ........................... ........................... ............................ ........................... ........................... ............................. ............................. ...................... ........ 7-1 Backup Backup Option............... Option............................. ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................. .................... ..... 7-1 Digital Input Filter Time Field .......................... ....................................... .......................... .......................... .......................... .......................... .......................... ............................ .................. ... 7-2 Serial Ports Field .......................... ........................................ ........................... ........................... ........................... ........................... ........................... ........................... ............................ ...................... ........ 7-2 Lockout Lockout and Log Options Options Field............................ Field.......................................... ............................ ............................ ........................... ........................... ........................... ........................ ........... 7-2 Using Interaction Page 9 Display with an Operator Station .......... ........... ........... ............ ........... ........... ........... ..... 7-2 Startup .......................... ........................................ ............................ ........................... ........................... ............................ ........................... ........................... ............................. ............................. ...................... ........ 7-4 Backup Backup Option Field ............................ ......................................... ........................... ............................ ............................ ........................... ........................... ............................ ........................... ............. 7-4 Stat Page Field..................... Field.................................. ........................... ........................... ........................... ........................... ........................... ........................... ............................ ............................. ................. ... 7-4 DIO Inventory Inventory Field .......................... ....................................... ........................... ............................ ............................ ........................... ........................... ............................. ............................. ................ 7-4 Digital Input Filter Time Field .......................... ....................................... .......................... .......................... .......................... .......................... .......................... ............................ .................. ... 7-5 Analog Analog Input Inventory Inventory Field .......................... ........................................ ............................ ............................ ............................ ............................ ........................... ........................... ................ 7-5 Redundant Redundant I/O Address Address Ranges Ranges Field..................... Field.................................. ........................... ........................... ........................... ........................... ............................. ........................ ........ 7-5 Lockout Lockout and Log Options Options Field............................ Field.......................................... ............................ ............................ ........................... ........................... ........................... ........................ ........... 7-5 Serial Ports Field .......................... ........................................ ........................... ........................... ........................... ........................... ........................... ........................... ............................ ...................... ........ 7-5 Interaction Interaction Page 10................................ 10.............................................. ........................... ........................... ............................ ............................ ............................ ............................ ............................ ................ 7-6 Event Queue Queue Pointer Information................ Information.............................. ........................... ........................... ........................... ........................... ............................ ............................ .................... ...... 7-7 Interaction Interaction Page 11................................ 11.............................................. ........................... ........................... ............................ ............................ ............................ ............................ ............................ ................ 7-8 Interaction Interaction Page 12................................ 12.............................................. ........................... ........................... ............................ ............................ ............................ ............................ ............................ ................ 7-9 Interaction Interaction Page 13................................ 13.............................................. ........................... ........................... ............................ ............................ ............................ ............................ ........................... ............. 7-10
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Contents
CHAPTER 8 ..................................................................................................................... 8-1 Alarms and Diagnostics .............................................................................................................................................. 8-1 Annunciation of Alarms ............................................................................................................................................ 8-1 Front Panel Numeric LEDs ............................................................................................................................... 8-1
v
Preface
The Distributed Processing Unit described in this publication consists of two models, the Model PDP001 Series and the Model PDP100 Series. From a hardware perspective, the two models are virtually identical. At the software level, however, the two models contain different firmware. The Version 7.1 Firmware makes the Model PDP100 Series compatible with the IEC 1131-3 toolset. The Model PDP001 Series supports Metso Automation MAX Controls EXtended Control Engineering Language (ExCEL), a Metso Automation MAX Controls programming language, and ladder logic. In addition to DPU front panel controls, to a limited extent you may control a DPU from the maxSTATION running maxVUE Runtime software. maxVUE Runtime also lets you monitor DPU status, DPU-related alarms, and access DPU Interaction Pages, containing data and system statistics stored in the DPU. Interaction Pages are described in Chapter 3. For maxVUE Runtime information, refer to Publication 277557, MaxSTATION Operator' s Guide. You may reload a DPU's configuration from the maxSTATION running maxTOOLS software. Refer to the maxTOOLS online help supplied with the package for configuration installation instructions.
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Chapter 1 Introduction Distributed Processing Unit Functionality The Model PDP Distributed Processing Unit (DPU) performs primary data acquisition, control, and data processing functions for the maxDNA Distributed Control System. The DPU is a self-contained microprocessor based, rack-mounted unit, which occupies a single slot in a Remote Processing Unit cabinet. It is designed to operate with user-defined combinations of maxDNA Model IOP Input/Output Modules, and to communicate with other devices, such as Programmable Logic Controllers and Remote Terminal Units. As a station on the DPU Bus, the DPU scans and processes information for use by other devices in the maxDNA system. Each DPU performs: •Comprehensive alarming and calculations. •Logging of Sequence of Events (SOE) data. •Acquisition of trend information. •Continuous scanning of Model IOP I/O modules. •Execution of predefined Control and Data Blocks for process control and data acquisition. •Execution of user written programs using IEC1131-3 Toolset or Metso Automation MAX Controls EXtended Control Engineering Language (ExCEL). •Ladder logic processing. •Assurance of secure link-level data highway communications.
Distributed Processing Unit Hardware A DPU consists of three circuit cards installed in a rack-mounted chassis. The right front chassis panel contains two clockwise and counter-clockwise connectors, two serial ports, 10 terminal blocks, and the DPU keylock.
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Model PDP DPU Installation, Preparation and Adjustment
The processor cards mounted behind the gray and white front panel consist of the motherboard, Data Highway Card, and the Control Processor Card. The Data Highway Card and Control Processor Card are mounted as daughter cards on the motherboard. Except for the Control Processor Card, the front edge of each processor card features switches, indicator lamps, and rotary dials that are visible and accessible from the DPU front panel.
Distributed Processing Unit Specifications Operating temperature range
0 to 60 degrees C
Storage temperature range
(-)25 to 70 degrees C
Relative humidity range
5 to 90% noncondensing
Power requirements
24 Vdc ±4 Vdc, 1.2 amps
Mounting the DPU The Model PDP Distributed Processing Unit (DPU) is mounted on the Input/Output (I/O) backplane with Model IOP Input/Output modules.
Positioning the DPU The DPU must be mounted in the right most position of the Model IOP rack since the DPU is wider than the I/O cards and requires good air flow. In a six-wide I/O rack, the mounting bracket to the left of the DPU must be removed since the DPU requires an I/O panel. When using a second DPU for backup, it must be mounted vertically adjacent to the primary DPU. When the DPU is installed in the right most slot, the DPU cover extends over the J3 and J4 connectors on the back panel. The standard daisy-chain cable (064353) is low profile, however, and will not cause any interference. Any cables higher than 1 inch above the surface of the backplane, and any terminators, will interfere with the cover. Some older cables, in particular, will interfere with the DPU cover. It may be possible to move the terminator to the other end of the daisy-chain or to rearrange the order of the daisy-chain cables to eliminate the interference. If this is not possible, a cable adapter is available (Metso Automation MAX Controls Part Number 081580). This adapter has a metal bracket which mounts to the power strut and a 12-inch connecting cable plugs into J3 or J4 on the back panel. It is a male-female adapter so that the original cable or
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Introduction
terminator can be plugged directly into the adapter out of the way of interference with the DPU. The DPU is designed to allow installation and removal with the +24 V dc power supply turned on.
Mounting Procedures Before mounting any hardware, refer to the cabling and field wiring sections of Publication 277563, Model IOP Input/Output System Installation and Pre paration, for information also pertinent to mounting. To install the DPU in the rack, refer to Chapter 6.
Wiring the DPU With the exception of the 10 point terminal block on the front panel of the DPU chassis, no hard wiring is required. All connections between the DPU module and the DPU chassis are made upon installation into the I/O rack. Use maxTOOLS to create input designations for each DPU during configuration. Ten terminal board connectors, with #6 screws, are positioned at the lower left side of the DPU chassis. Pin-outs are as follows: Table 1-1. Ten Point Terminal Block
PIN No. 1-6
Purpose Reserved
7
Open
8, 9
DPU offline contact (photovoltaic relay, opens when the DPU is offline) Peak operating voltage = ±300V Maximum load = 60 mA On resistance = 30 Ohms Off resistance = 1 mOhms (Contact is closed if DPU is online)
10
Circuit Ground
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Chapter 2 DPU Front Panel
Mode Select 1
0
CW
8 4 2 1
Off On CCW
Overview
Off
Data Highway
On
All DPU controls, indicator lamps, keylock, and switches are located on the DPU front panel. Refer to Figure 2-1, DPU Front Panel. Use this front panel to monitor or control different aspects of the DPU. This chapter describes and illustrates individual sections. The various front panel features are generally positioned in two vertical panel areas corresponding to supporting processor card positions mounted behind the front panel.
Jabber
Status
Stn No.
IOM Load
G Active R Offline Y Inactive
State Battery Power 1 Serial Ports 2
G- Tx R- Rx
DI
Mode Select DIP Switch Settings
G- Active R- Error
The mode switches, located at the top of the front panel, are used during DPU manufacturing and testing. For normal DPU operation, all four switches should be set to the left. Setting the B (Blank database) SW8, 2, 1 to the left, and SW4 to the right during power on or reset causes the DPU to erase its database and come up cold. Once the DPU is operational (DPU on DPU Bus), be sure to set the mode switches back to the left.
ti U
DO Per IO Prog IO
n
Tx Backup Rx
g ni s s e c o
Reset
r
P
CPU Load
d et u bi rt
Backup Link
si D
Takeover
Figure 2-1. Front Panel
DPU
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Pri PIO SIO1 SIO2
Sep
Model PDP DPU Installation, Preparation and Adjustment
Data Highw ay Area The Data Highway Area, (Figure 2-2), located in the upper right area of the gray front panel, consists of: •Two toggle switches used to intentionally break the CW and/or CCW highway connections to this DPU to simulate communications loss for systems testing (e.g., cable break reporting) without actually disconnecting cables. •Jabberhalt error LED to indicate timeout of excessively long transmissions. •Two rotary switches to provide the station address; r efer to next section. •Two LED displays; refer to "Two LED Displays." There are no internal switches or jumpers to be set during installation.
Figure 2-2. Upper Front Panel Area
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DPU Front Panel
Using Rotary Switches to Set Station Address Use the two rotary switches to configure a unique DPU highway station address, a number ranging from 32 and 63; the station number is set in hexadecimal (hex). The upper switch sets the most significant digit of the address (e.g., 3 for Station 50). The lower switch sets the least significant digit for the address (e.g., 2 for Station 50). Hexadecimal 0 1 2 3 4 5 6 7 8 9 A B C D E F
Decimal 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
To convert a two-digit hexadecimal number to decimal, multiply the first digit by 16 and add the decimal value of the second digit. 2C hex = 2 * 16 + C = 32 + 12 = 44 To convert decimal to hexadecimal, divide the decimal number by 16 until a remainder of less than 16 is obtained: 50 decimal
= 50÷16 = 3 (hex) with 2 (2 hex) remainder = 32 hex
Two LED Displays The two seven-segment LED displays report highway status using hex numbers. During DPU startup, the LEDs display FF. When the DPU concludes its startup phase, the LEDs alternately display the codes 03, 04, and 07 to indicate: (03) query response transfer is in progress (04) token passing is in progress (07 the DPU is executing normal background functions If an error occurs in the DPU, causing it to fail, these LEDs display an error code. Refer to Chapter 8 for a listing of error codes.
IOM Load Metso Automation MAX Controls Factory Service use only.
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Model PDP DPU Installation, Preparation and Adjustment
Status Section (LEDs) The middle area of the front panel contains 11 tri-colored LEDs (green, red, and yellow). Refer to Figure 2-3. The LEDs indicate the status of a variety of tasks, such as I/O bus scanning. Refer to the following tables for a list of definitions for the color-coded LEDs.
DPU Hardware Status LEDs The first three LEDs specifically relate to DPU hardware status. LED
What the Colors Mean
Active Offline Inactive
Green = DPU online and active. Red = DPU offline. Yellow = DPU online but inactive (backup pair).
Battery
Red = nickel cadmium or lithium battery bad. Yellow = nickel cadmium battery under test. Green = both batteries good.
Power
Green = DPU powered.
Figure 2-3. Status LEDs
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DPU Front Panel
Serial I/O and DPU Status Section LED
What the Colors Mean
Serial port1
Green = serial port 1 transmitting. Red = serial port 1 receiving.
Serial port2
Green = serial port 2 transmitting. Red = serial port 2 receiving.
Status Section LED Indicators DI
Fast Digital Input Scanning:
green = red = yellow = off = DO
all points good all points bad some points good and some points bad no points executing Fast Digital Output Scanning:
green = red = yellow = off = Per IO
all points good all points bad some points good and some points bad no points executing Periodic Input/Output scanning Analog Inputs, Control Blo cks, Data Blocks
green = red = yellow = off = Prog IO
all points good all points bad some points good and some points bad no points executing ExCEL Input/Output Scanning
green = red = yellow = off =
all points good all points bad some points good and some points bad no points executing
Backup Status LEDs The following two LEDs report backup link status. LED
What the Colors Mean
RX TX
green = Receiving data. green = Transmitting data.
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Model PDP DPU Installation, Preparation and Adjustment
Reset Button The Reset pushbutton does not produce a true hard reset; when you press this button, the DPU receives a false indication of impending +24 Volt power loss, causing the DPU to save the database into flash memory and wait for a power down that never occurs. However, a deadman timer associated with the Control Processor Card will cause a true hard reset after this routine finishes, after which a cool initialization will occur.
Backup Link When used with a backup DPU, a cable (Part 081387) runs between this connector on both DPUs. When used without a backup DPU, a terminator (Part 081388) must be installed in this connector.
CPU Load For Metso Automation MAX Controls Factory Service use only.
Takeover Button When two DPUs are used in a backup configuration, press the Takeover button on one of the DPUs to force that DPU to take control, making the other inactive.
Backup DIP Switch Settings Use the four-position backup DIP switch to select various DPU backup configurations. If backup is not configured, the top most switch should be set to the right and the others to the left. Refer to Chapter 5. The first position (top) on the DIP switch lets you designate the DPU as primary or secondary. Primary is to the right. The second position designates a separate or shared parallel input/output bus. Common (Shared) is to the left. Separate is to the right. Note: if you are configuring a mixed I/O system using some shared and some separate I/O with a Y-Adapter, select Separate.
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DPU Front Panel
The third position designates a separate or shared link connected to serial port 1. Separate is to the right. Common (Shared) is to the left. The fourth position designates a separate or shared link connected to serial port 2. Separate is to the right. Common (Shared) is to the left.
DPU Keyswitch Use the DPU keyswitch, located at the bottom part of the DPU chassis, to select one of three operator modes. The DPU can operate with the key in place or removed; you can remove the key from the switch regardless of key position. The keyswitch may be placed in one of the following three positions: Run
Keyslot horizontal The DPU executes the functions defined in its point database. In this mode, you are permitted to reload a DPU database; however you cannot configure Interaction Page 9.
Offline
Keyslot diagonal, one-quarter turn counterclockwise from Run. In this mode, the DPU scans inputs but does not execute outputs. To service the DPU, you may manually select offline by turning the keyswitch to this position. Offline is imposed automatically with the keyswitch in run or locked position when a fatal diagnostic is detected.
Locked
Keyslot diagonal, one-quarter turn clockwise from Run. In this mode, the DPU executes the functions defined in its point database. Reloads and database changes may or may not be permitted, depending on the DPU configuration as shown on Interaction Page 9.
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Chapter 3 Input/Output Connections Data Highway The upper left portion of the DPU chassis features two groups of male and female 9-pin D-type connectors used to connect the clockwise (CW) and counter-clockwise (CCW) DPU Bus cables. Positions J2 and J3 are for CW connections, and J4 and J5 are for CCW. For additional information on Input/Output connections, refer to Publication 277580, DPU Bus Cabling.
ACSII Ports Directly below the DPU Bus connections are two female 25-pin D-type connectors (J6 and J7) which serve as ASCII serial ports. Table 3-1 provides the pin-outs for both ports. These two ASCII ports provide linkage to programmable logic controllers, remote multiplexers, etc. Connections can be RS-232, RS-422, or RS-485, chosen without jumpers, with proper connection to the 25-pin D-Connectors. When you define a DPU via maxTOOLS, you may configure setup parameters, such as baud rate, parity, and number of stop bits. You may also enter setup information directly on Interaction Page 9. Remember, when you add this information, you must take the DPU offline. Table 3-1. ASCII Port Pin -out s (usabl e via ExCEL, Rev. 2) Pin No.
Purpose
24 2 23 3 4 5 7 1
Transmit Data Transmit Data Receive Data Receive Data Request-to-Send Clear-to-Send Circuit Ground Chassis Ground
Metso Automation MAX Controls • 277573
TxD + (RS-422) TxD - (RS-422), or TxD (RS-232/423) RxD + (RS-422) RxD - (RS-422), or RxD (RS-232/423) RTS (RS-232/423) CTS (RS-232/423)
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Chapter 4 DPU Battery and Fuse Maintenance Battery Types The Model PDP DPU uses two battery types that must be replaced periodically. A Nickel Cadmium (NiCd) rechargeable battery pack, mounted on the motherboard, allows the DPU to preserve its database when power goes down. This battery, tested for one minute every hour, will raise a "battery #2 weak" battery low alarm if it fails. The DPU Control Processor Card uses a 360 maH Lithium battery to preserve CMOS settings and time and date. If this battery fails, a "battery #1 weak" battery low alarm will be raised. The battery has a shelf life of 10 years under "no load" conditions. When the DPU is powered, the battery is electronically disconnected. The Control Processor Card battery will last for more than two years if no power is applied to the board. Caution: The DPU contains devices that can be damaged by electrostatic discharge. It is imperative that the DPU be carried in antistatic protective bags. Grounded workstations and wrist straps must be used when adjusting or performing any work on the DPU. If soldering irons are used, they must also be grounded.
Replacing the NiCd Battery Pack (Battery #2) Note: when the DPU is shipped or put in storage, always unplug the NiCd battery pack from the P10 connector.
The DPU NiCd battery pack (Part number 081537) should be replaced at least every three years. Spare NiCd battery packs have a shelf life of 5 to 7 years. The battery is located in an accessible compartment on the upper right side of the DPU. To access the battery, you must remove the DPU from the rack as described in the following procedure:
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To replace the battery: 1. Important: If the DPU to be serviced is part of a DPU pair, use the instructions in Chapter 6, "Replacing a DPU in a Backup Pair," to extract the DPU. If the DPU to be serviced is configured standalone, place the keyswitch in the offline position and use the following instructions. Gently slide the DPU module out of the cabinet rack and set the unit down on an appropriate work surface, component side up. 2.
Locate the battery compartment on the upper right side.
3.
Remove the battery plug connector from the P10 port.
4.
Remove the failed battery from its holder clips and dispose of it appropriately.
5.
Slide the new battery pack in between the holder clips and plug the battery's plug connector into the P10 port.
6.
Install the DPU in the chassis using the appropriate procedure found in Chapter 6," Starting a Standalone DPU," or "Replacing a DPU in a Backup Pair."
Replacing the Lithium Battery (Battery #1) The Lithium battery is mounted on the Control Processor board. Replace the battery with a 360mAh TLS186 Tadiran battery or equivalent. (Part number 081558). To replace the battery: 1. Important: If the DPU to be serviced is part of a DPU pair, use the instructions in Chapter 6, "Replacing a DPU in a Backup Pair" to extract the DPU. If the DPU to be serviced is configured standalone, place the keyswitch in the offline position and use the following instructions. Gently slide the DPU module out of the cabinet rack and set the unit down on an appropriate work surface, component side up.
4-2
2.
Remove the top metal cover.
3.
Locate the battery. It is on the top side of the Control Processor board near the DB25 connector.
4.
Carefully remove the battery by pulling it straight up. Do not use any metal tools since they could short the battery leads. Additionally, do
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not place any pressure on the circuits near the battery. 5.
Install the battery into the same connector from which the old battery was removed (B1). Make sure that the (+) lead, the center of the battery, plugs into the end pin of the connector marked with the (+) on the board. The second lead (-) should go into the fourth pin on connector B1.
6.
Install the metal cover.
7.
Install the DPU in the chassis using the appropriate procedure found in Chapter 6," Starting a Standalone DPU," or "Replacing a DPU in a Backup Pair."
Replacing DPU Fuses The DPU has two fuses, located on the motherboard, marked F1 and F2. Both fuses are subminiatures (resemble resistors). Fuse F1, 3A (Part number 014257), is used for external battery power. Fuse 2, 3A (Part number 014257), is used for 24V power. They are both mounted directly to the board by their leads and plugged into sockets. To change the fuses, follow the same procedure for changing the lithium battery, as described in the previous section, locate and replace the fuses.
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Chapter 5 Backing up the DPU Overview In a redundant configuration, two DPUs are connected to form a backup pair. One DPU is designated as the primary unit and the other DPU the secondary unit. The DPU Bus station address of the secondary station is one number greater than the address of the primary station. The installation, preparation, and adjustment procedures included in this publication apply to both DPUs in a redundant configuration. This chapter provides information on switches and cabling in a redundant configuration.
Automatic Failover/Manual Takeover Process control can be transferred automatically (Failover), or you can manually command takeover. Automatic Failover can only occur from the primary DPU to the secondary DPU; a secondary DPU will never automatically failover to a primary unless the secondary loses power or is reset.
Automatic Failover Process control is automatically transferred from the primary DPU to the secondary DPU when the primary DPU experiences a severe diagnostic alarm or when communication between primary and secondary DPU is lost. However, if the secondary DPU is itself experiencing a severe diagnostic alarm, it will refuse control, unless the primary DPU loses power or is reset. After the alarm condition in the primary DPU is rectified, acknowledge all remote alarms, confirm configuration using Interaction Page 9, and press the takeover button on the front panel of the primary DPU to return control.
Manual Takeover To manually command either DPU to assume control, press the takeover button on the front panel of the unit. Manual takeover will occur even if a severe diagnostic alarm or a fatal alarm condition exists in the DPU whose button is pressed.
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If you manually transfer to primary while the primary has a severe diagnostic alarm, automatic failover may cause control to transfer back to the secondary when you release the Takeover button, as described above.
Cable Disconnect The backup serial link cable (Part number 081387) carries data signals between the primary and secondary DPUs, as well as a status signal which determines which DPU is active. If one end of this cable is removed from either DPU, that unit is rendered inactive. If a DPU is not part of a backup pair, a terminator (Part number 081388) must be inserted in place of the cable.
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Chapter 6 Starting the DPU Startup States Refer to this chapter to learn how to: • Start a standalone DPU • Start DPUs in a backup pair • Replace a DPU in a backup pair When a DPU is restarted, it senses the type of initialization being performed and starts in one of the following two modes: Cold
A Cold initialization occurs following a power outage if no configuration information is available from before the outage. This can occur if no battery power is available when the DPU is powered down, or if a Cold start is demanded through the front panel mode switches. Following a Cold start, the DPU will remain in Offline state until it is manually placed online. Refer to "Demanding a Cold Startup."
Cool
A Cool initialization occurs if configuration data is available in flash memory, unless a Cold start is demanded through the front panel mode switches. Following a Cool start, the DPU will automatically progress to Online state unless its keyswitch is in the Offline position.
In both modes, the DPU uses the time and date preserved in its CMOS clock, then synchronizes with other stations on the DPU Bus. If the CMOS clock is not valid, the DPU will raise an alarm and remain Offline until it receives time via the DPU Bus. When the DPU is reset or the 24 Vdc power to the DPU is interrupted, Event Queue information is lost, but the internal battery allows the configuration to be preserved in flash memory. When the DPU restarts, it reloads its configuration and erases the flash memory to prevent the possibility of later reloading an out of date configuration.
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Demanding a Cold Startup When a DPU is first placed in service, or when a DPU is moved from one location to another, it is advisable to clear any previous configuration data that may remain in its flash memory. To do this, before applying power to the DPU, set front panel mode switches 1, 2, and 8 to the left, and mode switch 4 to the right. After the DPU has gone through its startup sequence as described in "Starting a Standalone DPU," be sure to set mode switch 4 back to the left to prevent future Cold startups.
Starting a Standalone DPU Perform the following steps to ensure that a DPU is completely configured before it is allowed to assume control. It is important that the DPU not be placed in the Online state until it has been fully configured. To start a standalone DPU:
6-2
1.
Turn the DPU keylock to the Offline position (fully counter-clockwise).
2.
Insert a terminator (Part number 081388) in the backup link connector.
3.
On the backup DIP switch at the bottom of the DPU, set the top most switch to the right (primary).
4.
Set front panel mode switches 1, 2, and 8 to the left, and set mode switch 4 to the right to demand a Cold startup, as described in the preceding section.
5.
Verify that the NiCd battery pack is installed and plugged correctly into P10 connector on the motherboard. Additionally, verify that protective connectors (Part number 081389) are installed in the IOM and CPU load connectors.
6.
Set the proper DPU Bus address in the station number switches.
7.
Position the module into the top and bottom card guides of the chassis.
8.
Carefully slide the module forward, verifying that the connector pins on the solder side of the module engage the corresponding contact guides on the chassis assembly.
9.
When the contacts are engaged and resistance is felt, firmly press on the front panel of the module front plate to make the simultaneous connections at the front and rear. Apply pressure to the left of the LEDs to place the force directly in line with the printed circuit card of the module.
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Starting the DPU
10.
Secure module to chassis assembly with the top and bottom lock down screws on the front of the module.
11.
Before it begins DPU Bus communications, the DPU will initially display FF as its front panel LEDs, progress through a series of steps counting down from 0F to 06. Once it begins communicating, a healthy DPU will display a rapidly flickering number whose value is predominantly 07.
12.
Return mode switch 4 to the left.
13.
Reload the DPU using maxTOOLS at a maxSTATION Dump/Reload mode at the Operator Station.
14.
Acknowledge all alarms from the DPU and make sure that they all clear.
15.
Display Interaction Page 9 of the DPU at a maxSTATION. Locate the Backup? Field and type n for no; locate the Startup? Field and type y for yes.
16.
Place the keyswitch in the Run or Locked mode.
or the
Starting a Backup Pair of DPUs When starting a backup pair of DPUs, you must bring the primary DPU up first and make sure it is running properly before starting the secondary. Perform the following steps to ensure that an unexpected failover does not occur during the startup process. To start DPU backup pairs: 1.
Turn both DPU counter-clockwise).
keylocks
2.
Set the top most backup DIP switch appropriately for each DPU (to the right for primary, to the left for secondary).
3.
Set the remaining backup switches (shared/separate I/O) appropriately as described in Chapter 2,"Backup DIP Switch Settings"; make sure the corresponding switch positions match in each DPU.
4.
On each DPU, set front panel mode switches 1, 2, and 8 to the left; set mode switch 4 to the right to demand Cold startups from each unit.
5.
Verify that the NiCd battery pack is installed and plugged correctly into P10 connector on the motherboard. Additionally, verify that protective connectors (Part number 081389) are installed in the IOM
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the
Offline
position
(fully
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Model PDP DPU Installation, Preparation and Adjustment
and CPU load connectors.
6-4
6.
Set the proper DPU Bus address in the station number switches.
7.
Position each DPU into the top and bottom card guides of each chassis, but DO NOT push them in far enough to apply power to the units.
8.
Connect a backup cable (Part number 081387) between the units. Note that the cable ends are keyed so that they can only be inserted one way.
9.
For the primary, carefully slide the module forward, verifying that the connector pins on the solder side of the module engage the corresponding contact guides on the chassis assembly.
10.
When the contacts are engaged and resistance is felt, firmly press on the front panel of the module front plate to make the simultaneous connections at the front and rear. Apply pressure to the left of the LEDs to place the force directly in line with the printed circuit card of the module.
11.
Secure module to chassis assembly with the top and bottom lock down screws on the front of the module.
12.
Before it begins DPU Bus communications, the DPU will initially display FF as its front panel LEDs, progress through a series of steps counting down from 0F to 06. Once it begins communicating, a healthy DPU will display a rapidly flickering number whose value is predominantly 07.
13.
Return mode switch 4 to the left.
14.
Reload the primary DPU using maxTOOLS at a maxSTATION or the Dump/Reload mode at an Operator Station.
15.
Acknowledge all alarms from the primary DPU.
16.
Display Interaction Page 9 of the DPU at a maxSTATION or Operator Station. Locate the Backup? Field and type y for yes; locate the Startup? Field and type y for yes.
17.
Place the keyswitch of the primary DPU in the Run or Locked mode.
18.
Insert the secondary card using the same steps as the primary.
19.
Make sure the secondary starts up and begins communicating on the DPU Bus as described above.
20.
Return mode switch 4 to the left.
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Starting the DPU
21.
Reload the secondary DPU using maxTOOLS at a maxSTATION or the Dump/Reload mode at an Operator Station.
22.
Acknowledge all alarms from the DPU pair and make sure that secondary alarms are all clear.
23.
Display Interaction Page 9 of the DPU at a maxSTATION or Operator Station. Locate the Backup? Field and type y for yes; locate the Startup? Field and type y for yes.
24.
Make sure that the primary DPU is displaying the alarm Backup Link Timeout to make sure there are no higher priority alarms.
25.
Place the keyswitch of the secondary DPU in the Run or Locked mode.
26.
Acknowledge all DPU alarms and make sure they all clear.
Replacing a DPU in a Backup Pair When replacing a DPU in a backup pair, it is necessary to prevent the new unit from gaining control until it is properly configured and up to date. Perform the following steps to ensure that an unexpected failover does not occur during the replacement process. To replace a DPU in a backup pair: 1.
Make sure there are no severe outstanding alarms from the DPU which is to remain in service, then press its Takeover switch.
2.
Turn the keylock of the DPU being replaced to the Offline position (fully counter-clockwise).
3.
Without disconnecting any cables, pull the DPU being replaced far enough out of its chassis to disconnect power, then wait until all its LEDs have turned off; this may require up to 30 seconds.
4.
Disconnect the backup cable from the DPU being replaced; DO NOT disconnect the other end of the cable from the DPU which is to remain.
5.
On the new DPU, verify that the NiCd battery pack is installed and plugged correctly into P10 connector on the motherboard. Additionally, verify that protective connectors (Part number 081389) are installed in the IOM and CPU load connectors.
6.
Replace the DPU with the new unit, position the new DPU into the top and bottom card guides of the chassis, but DO NOT push the new
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Model PDP DPU Installation, Preparation and Adjustment
unit in far enough to apply power to it.
6-6
7.
Set the backup DIP switches on the new DPU to match the unit which was removed.
8.
Set the station number rotary switches to match the unit that was removed.
9.
Set front panel mode switches 1, 2, and 8 to the left, and set mode switch 4 to the right to demand a Cold startup.
10.
Connect the backup cable to the new DPU. Note that the cable end is keyed so that it can only be inserted one way.
11.
Carefully slide the module forward, verifying that the connector pins on the solder side of the module engage the corresponding contact guides on the chassis assembly.
12.
When the contacts are engaged and resistance is felt, firmly press on the front panel of the module front plate to make the simultaneous connections at the front and rear. Apply pressure to the left of the LEDs to place the force directly in line with the printed circuit card of the module.
13.
Secure module to chassis assembly with the top and bottom lock down screws on the front of the module.
14.
Before it begins DPU Bus communications, the DPU will initially display FF as its front panel LEDs, progress through a series of steps counting down from 0F to 06. Once it begins communicating, a healthy DPU will display a rapidly flickering number whose value is predominantly 07.
15.
Return mode switch 4 to the left.
16.
Reload the new DPU using maxTOOLS at a maxSTATION or the Dump/Reload mode at an Operator Station.
17.
Acknowledge all alarms from the new DPU.
18.
Display Interaction Page 9 of the new DPU at a maxSTATION or Operator Station. Locate the Backup? Field and type y for yes; locate the Startup? Field and type y for yes.
19.
If the new DPU is the primary of the pair, make sure the secondary is displaying the alarm DPU Pair is Running on Secondary. If the DPU being replaced is the secondary, make sure the primary is displaying the alarm Backup Link Timeout. This is done to make sure that there are no higher priority alarms.
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20.
Place the keyswitch of the new DPU in the Run or Locked mode.
21.
If the new DPU is the primary of the pair, wait at least 10 seconds to allow its database to be updated, then press its Takeover button to give it control.
22.
Acknowledge all DPU alarms and make sure they all clear.
23.
If the DPU is to be shipped or put in storage, unplug the NiCd battery pack from the P10 connector.
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Chapter 7 Using Interaction Pages Accessing Displays You may access Interaction Page displays 9 through 13 from the maxSTATION to view information and data specifically related to the DPU. These specific Interaction Pages are covered in this chapter in some detail. To access an Interaction Page display: 1.
Bring up the maxVUE Runtime main menu.
2.
Click the System Status button on the standard Vertical Toolbar to open the System Status display.
3.
Click the Int Page button appearing on the Horizontal Toolbar.
Using Interaction Page 9 Display with a Workstation Use Interaction Page 9 to display the DPU configuration data sent by a Work-Station. Refer to Figure 7-1.
Startup The Startup? prompt appears when manual intervention is required, following a cold startup or fatal alarm. For example, an I/O module fails and is not configured as an alarm-only module.
Backup Option DPUs can be paired in a redundant configuration as described in Chapter 5. To configure the backup option, enter Y in the Backup field.
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Digital Input Filter Time Field Digital Input Filter time is in milliseconds; the default is 10 milliseconds. This digital filter can be used in place of, or with, the jumper enabled hardware lag filter on the Model IOP DI modules.
Serial Ports Field You may connect asynchronous serial devices to serial ports 1 and 2. The protocols and parameters for these devices are configured here. For additional information about serial links, refer to Publication 277574 , DPU Embedded Serial Links User's Guide.
Lockout and Log Options Field In the Lock position, you may disallow certain data DPU Bus operations from MIS, HOST, REloads, or Screen Edits.
DPU Configuration Page
Revision Level
Date 14/OC/96 Time 09:32:12
MODE Run
DHW 5.0 CP 5.0 IOM 5.0
Model 530 Configuration Stat Page
Active Backup N
DIGITAL FILTER TIME 10 MSEC
SERIAL I/O PORTS Port No
Baud Rate
Link Type (0-255)
Bits/Char (5,6,7,8)
Stop (1,2)
Parity (O,E,N)
XON/OFF IN OUT
RTS/CTS IN OUT
J6 J7
9600 9600
25 MODB 214 Umax
8 8
1 2
O N
NN NN
NN NN
MIS MIS
N HOST? N HOST?
RELOAD? RELOAD?
SCREENS? N SCREENS? N
LOCK OUT ACTIONS LOG EDIT ACTIONS
Figure 7-1. Interaction Page 9 Display wit h Sample Configu ration .
Using Interaction Page 9 Display with an Operator Station Use Interaction Page 9 to configure the DPU if a Model 585 Operator Station is being used instead of a maxSTATION. Refer to Figure 7-2.
7-2
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Before you can edit configuration data on Interaction Page 9, you must place the DPU in offline mode. While you may make entries on this page only in Offline mode, they do not take effect until either Run or Locked mode is entered. Any questionable entries on this page are automatically highlighted in red. For example, you entered a Z instead of an I or O for a DIO module. The Interaction Page 9 section title, where the questionable entry was made, also becomes highlighted. HWY 1 STA 33 INTERACTION PAGE 9 DPU Configuration Page
Revision Level
Date 14/OC/96 Time 09:32:12
MODE Run
DHW 5.0 CP 5.0 IOM 5.0
Model 585 Configuration Stat Page 10
Active Backup? N
DIO Inventory 1 2 3 4 5 6 7 8
I = Input, 9 10 11 12 13 14 15 16
AI Inventory QUAD1 QUAD2 QUAD3 QUAD4
O = Output, 17 18 19 20 21 22 23 24
Address by 16
Alarm Only
A = Alarm Only 25 26 Digital 27 Filter Time 28 10 msec 29 30 31
Channels 1-15
Linearization
( 1-15) (16-30) (33-47) (48-62)
AI PAGE DATA PT
14 15 14 15
14 15 14 15
Redundant I/O Address Ranges (R = Redundant, C = Common) 0 C
16 C
32 C
48 C
64 C
80 C
96 C
112 C
128 C
144 C
160 C
176 C
192 C
208 C
224 C
SERIAL I/O PORTS Port No
Baud Rate
Link Type (0-255)
Bits/Char (5,6,7,8)
Stop (1,2)
Parity (O,E,N)
XON/OFF IN OUT
RTS/CTS IN OUT
J6 J7
9600 9600
25 MODB 214 Umax
8 8
1 2
O N
NN NN
NN NN
N HOST? N HOST?
RELOAD? RELOAD?
LOCK OUT ACTIONS LOG EDIT ACTIONS
MIS? MIS?
SCREENS? N SCREENS? N
Figure 7-2. Interaction Page 9, Operator Station Version.
The DPU will not become active until Interaction Page 9 is completely configured and the keylock switch is in the Run or Locked position.
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Model PDP DPU Installation, Preparation and Adjustment
The following sections describe the expected entries and automatic defaults on Interaction Page 9.
Startup The startup? prompt appears when manual intervention is required following a cold startup or fatal alarm. (For example, an I/O module fails and is not configured as an alarm-only module.) After Interaction Page 9 is reviewed and configured, enter Y in the entry field to place the DPU into operation. Ensure that the keyswitch is in the Online (Run or Locked) position.
Backup Option Field DPUs can be paired in a redundant configuration as described in Chapter 5. To configure the backup option, enter Y in the Backup field.
Stat Page Field This field determines what is shown on Interaction Page 8. The default for this field, 10, places the I/O status and event queue display on page 8. During configuration this field may be changed to 11, DPU Serial Links Status; 12, DPU Bus Performance Statistics; or 13, High Speed Digital I/O Tabular Display.
DIO Inventory Field The Digital Input/Output (DIO) Inventory can accept 30 entries in the ranges 1 to 15 and 17 to 31. Enter I or O to indicate input/output modules. Examples:
1
I
2
O
Append an A to indicate that loss or failure of one or more of these modules is not a fatal alarm, as would be the default. (Any fatal alarm forces the DPU to Offline mode.) Examples:
7-4
1
I
2
O
3
IA
4
OA
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The default is all blank fields. When no module at a given address is desired, enter blanks at that location. Note that DIO modules need not be at consecutive addresses. For Fast Digital Inputs, a maximum of 25 digital input boards can be used.
Digital Input Filter Time Field Digital Input filter time is in milliseconds; the default is 10 milliseconds. This digital filter can be used in place of, or with, the jumper enabled hardware lag filter on the Model IOP DI modules.
Analog Input Inventory Field The Analog Input (AI) Inventory field on Interaction Page 9 contains three columns. Each column can accept four entries. The first column is for the four potential high-level Al modules needed to fill the Analog (Process) Inputs Page. Enter the base module number (divisible by 16, and greater than or equal to 32). The second column is for As to specify alarm only. Use the third column to specify the number of channels to be scanned of the 15 possible channels. This field is used when Quad PAT output modules are used. For example, if two PAT output modules, with addresses of 48 and 62, are used, quad one could be configured for address 48, with eight channels scanned. Defaults are all blank fields.
Redundant I/O Address Ranges Field When the Y adapter is used for a combined shared and redundant I/O bus, ranges of modules must be specified as either redundant (R), common (C), or blank if no modules reside in the specified range. For example, address 16 represents address ranges 16 through 31.
Lockout and Log Options Field In the Lock position, you may disallow certain DPU Bus operations from MIS, HOST, REloads, or Screen Edits.
Serial Ports Field You may connect asynchronous serial devices to serial ports 1 and 2. The protocols and parameters for these devices are configured here. For additional information about serial links, refer to Publication 277574, DPU Embedded Serial Links User's Guide.
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Model PDP DPU Installation, Preparation and Adjustment
Interaction Page 10 The I/O Module Status display shows all possible addresses on the I/O bus. The status of each address (active, standby, communication problem or no module) is highlighted in either green, yellow, red or black.
I/O MODULE STATUS
0 1 2 16 17 18 32 33 34 48 49 50 64 65 66 80 81 82 96 97 98 112 113 114 128 129 130 144 145 146 160 161 162 176 177 178 192 193 194 208 209 210 224 225 226 240 241 242 Last Bad Module =
3 19 35 51 67 83 99 115 131 147 163 179 195 211 227 243
4 20 36 52 68 84 100 116 132 148 164 180 196 212 228 244
5 21 37 53 69 85 101 117 133 149 165 181 197 213 229 245
6 22 38 54 70 86 102 118 134 150 166 182 198 214 230 246
7 23 39 55 71 87 103 119 135 151 167 183 199 215 231 247
8 24 40 56 72 88 104 120 136 152 168 184 200 216 232 248
9 25 41 57 73 89 105 121 137 153 169 185 201 217 233 249
10 26 42 58 74 90 106 122 138 154 170 186 202 218 234 250
11 27 43 59 75 91 107 123 139 155 171 187 203 219 235 251
12 28 44 60 76 92 108 124 140 156 172 188 204 220 236 252
13 29 45 61 77 93 109 125 141 157 173 189 205 221 237 253
14 30 46 62 78 94 110 126 142 158 174 190 206 222 238 254
15 31 47 63 79 95 111 127 143 159 175 191 207 223 239 255
EVENT QUEUE POINTERS PUT 01 02 03 04 05 06 07
8489F4 820230 820230 820230 820230 820230 820230 820230
20 00 00 00 00 00 00 00
08 09 10 11 12 13 14 15
820230 820230 820230 820230 820230 820230 820230 820230
00 00 00 00 00 00 00 00
16 17 18 19 20 21 22 23
820230 820230 820230 820230 820230 820230 820230 820230
00 00 00 00 00 00 00 00
24 25 26 27 28 29 30 31
820230 820230 820230 820230 820230 820230 820230 820230
00 00 00 00 00 00 00 00
Figur e 7-3. Interact ion Page 10, I/O Module Status and Ev ent Queue Point ers.
Green (Model IOP I/O) or blue (Field I/O) highlighting indicates that an I/O module is present at that address and there are no communication problems with the module. In a redundant I/O backup configuration, the module address can assume this color in both the active and inactive DPUs. Yellow highlighting indicates that the system is set up for shared I/O (two DPUs with a common I/O string) and a module is present at that address. The module address is highlighted in yellow for the inactive DPU and will change to green when the DPU assumes control. Red highlighting indicates that some process (Data Blocks, Process Inputs, Control Blocks, or ExCEL) is trying to access a module at that address but either no module is present or the module has a communication problem. If the communication problem is intermittent, the address will only be red for 4
7-6
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seconds after the last unsuccessful scan. In the case where only ExCEL is trying to access the module, ExCEL must access the module frequently enough for the error to persist.
SERIAL PORT J6 ExCEL
OK TRANSACTIONS
0
NO. OF DATA BLOCKS NO. OF MESSAGES/SCAN LINK SCAN TIME (MS)
0 0 0
INPUT QUEUE OUTPUT QUEUE 0
0
BUFFER OVERRUNS CHECKSUM ERRORS FAILED TO SENDS LINK LEVEL ERRORS RETRIES TIMEOUTS UNEXPECTED CHARACTERS LAST NAK CODE
0 0 0 0 0 0 0 0
BUFFER OVERRUNS CHECKSUM ERRORS FAILED TO SENDS LINK LEVEL ERRORS RETRIES TIMEOUTS UNEXPECTED CHARACTERS LAST NAK CODE
0 0 0 0 0 0 0 0
SERIAL PORT J7 ExCEL OK TRANSACTIONS
0
NO. OF DATA BLOCKS NO. OF MESSAGES/SCAN LINK SCAN TIME (MS)
0 0 0
INPUT QUEUE OUTPUT QUEUE
0 0
Figur e 7-4. Interact ion Page 11, Serial Port Statu s Displ ay.
Black highlighting indicates that no I/O module is present and no process is attempting to access that address. Note that if two modules are present at the same address, the DPU will not be able to communicate with either module and the display will indicate that no module is present. The Last Bad Module statistic field displays the address and time of the most recent unsuccessful I/O scan.
Event Queue Pointer Information Interaction page 10 also contains Event Queue pointer information. The Event Queue is an internal DPU buffer used to store events such as Sequence of Events entries, process alarms, remote diagnostic alarms, time updates, and operator edit actions. The Event Queue pointer table shows the memory address (in hex) of the last event placed in the queue by the DPU (i.e., PUT XXXXXX YY), and the memory location of the last event removed from the queue by each of the 31 possible high traffic loop stations during normal operation (e.g., 01 XXXXXX YY). The last two digits in the field indicate how many times the queue has wrapped around.
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Model PDP DPU Installation, Preparation and Adjustment
Since the events are constantly being removed from the queue and processed by the stations on each scan, the addresses for active dequeueing stations (maxSTATIONs and Operator Stations) should be close to the address of the DPU PUT pointer.
HIGHWAY PERFORMANCE STATISTICS TIME MASTER ADDRESS LAST SENDER OF BAD DAT A TIME SYNC MSGS IGNORED
36 0 0
TOKEN PASSES PER SECOND= 2
COMMAND RESPONSE REJECTS
9
MASTERSHIPS RECEIVED = 26273 STATUS BROADCASTS = 65 TOTAL Q/R TRANSACTIONS = 1815 RECEIVED FRAMES WITH ERROR 101 UNFINISHED TRANSMIT QUERIES 0
LAST REJECTED STATION LAST REJECTED QUERY LAST REJECTED PTID TYPE LAST REJECTED PTID INDEX LAST REJECTED ITEM LINK REJECTS READ SINGLE ITEM WRITE SINGLE ITEM READ MULT ITEMS IEEE WRITE MULT ITEMS IEEE READ THESE ITEMS READ SINGLE ITEM/STS WRITE THESE ITEMS IEEE READ THESE ITEMS/QUALITY OLD SCAN TABLE MESSAGES NEW SCAN TABLE MESSAGES
30 25 FF FF FF 0 152 181 2 243 34 39 0 0 0 40
STATION =
36
CRC ERRORS = 2304 STALLOUT RECOVERIES = 0 OVERRUN ERRORS = 9 RECEIVE FRAME LENGTH ERRORS= 0 ABORTS RECEIVED = 0 ABORTS TRANSMITTED = 0 CTS LOST = 0 DCD LOST = 90 CTS NOT ACTIVE = 0 DCD ACTIVE AT TX TIME = 2 MESSAGE RETRIES = 160 UNEXPLAINED ERRORS = 0
HEX MEMORY DUMP 000000 TOTAL DHW DIAGNOSTIC ALARMS= 0 CW OPTICAL CABLE CHANGES = 0 CCW OPTICAL CABLE CHANGES= 0 CW ELECTRICAL CABLE CHANGES CCW ELECTRICAL CABLE CHANGES= 2 PERMANENT NEXT STATION ADDRESS = 48
D7 01 F4 IF F8 FF 2E 94 77 04 00 50 00 00 00 00 0
Figure 7-5. Interaction Page 12, Highway Performance Statistics Page.
Interaction Page 11 Interaction page 11 contains serial link statistics for PLC links and HCI links that may be connected to the serial ports of the DPU. Refer to Figure 7-4. These statistics are cleared during any offline to online transition. Refer to Publication 277574, DPU Embedded Links User's Guide, for more information about these statistics. Refer to the following table for a description of HCI link files.
7-8
OK TRANSACTIONS
Count of successful query/response transactions between the PC and DPU.
BUFFER OVERRUNS
Count of messages received from PC that were too long to be valid.
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CHECKSUM ERRORS
Count of queries received checksum errors from PC.
FAILED TO SENDS
Count of nonimmediate attempted to be sent.
UNEXPECTED CHARACTERS
Count of unexpected received from the PC.
with
queries
characters
All other statistics for HCI link are not valid.
Interaction Page 12 Interaction Page 12 contains the DPU Bus performance statistics display show-ing the diagnostic counters for the network. The statistics are cumulative from the last RZAP command, which is initiated from the Highway Status display on the maxSTATION. Refer to Figure 7-5, Interaction Page 12, Highway Performance Statistics Page. Refer to Publication 277581 for descriptions of each field appearing on the left side of the display. The following table describes the right column statistics appearing in Interaction Page 12: COMMAND REJECTs
RESPONSE
Count of the Immediate queries sent to this station that were rejected.
LAST REJECTED STATION
Highway address (in decimal) of the last station that issued an Immediate query that was rejected.
LAST REJECTED QUERY
Immediate query type (in decimal) of the last Immediate query that was rejected.
LAST REJECTED PTID TYPE
PTID type field (in hex) of the last database access failure. If the rejected query above does not use a PTID the type displayed will be FF.
LAST REJECTED PTID index
PTID slot/channel field (in hex) of the last database access failure. If the rejected query above does not use a PTID the index displayed will be FF.
LAST REJECTED ITEM
Item number (in hex) of the last database access failure. If the rejected query above does not use an item number field
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Model PDP DPU Installation, Preparation and Adjustment
the item displayed will be FF. READ SINGLE ITEM
Count of read single item queries processed by this DPU since reset.
WRITE SINGLE ITEM
Count of write single item and write single item IEEE queries processed by this DPU since reset.
READ MULT ITEMS IEEE
Count of read multiple items queries processed by this DPU since reset.
WRITE MULT ITEMS IEEE
Count of write multiple items queries processed by this DPU since reset.
READ THESE ITEMS
Count of read these items and read these items IEEE queries processed by this DPU since reset.
READ SINGLE ITEM/STS
Count of read single with status queries processed by this DPU since reset. The read single item with status query is normally issued by other DPUs and Model 552 controllers to perform Control Block and Data Block Receives.
Interaction Page 13 Interaction Page 13 contains the DIO tabular display; the fields are described below: Table 7-1. DIO Tabular Display.
TB01-TB32
Logical name of Fast DIO board 1-32.
T/F
Bit value: T = true = 1, F = False = 0. For each bit in automatic mode, its state (T/F) is shown on a yellow or green field background. For each bit in manual mode, its state is shown on a black background.
7-10
I/O address
Physical I/O bus address of TBxx. This value can be 0-239 (0 = phantom).
Module type
DIO I/O module type input (IN) or output (OUT).
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For modules configured to only alarm on failure, the type (IN or OUT) will be in black on a yellow or green field background. If the module is configured for a fatal error on failure (DPU goes offline), the type will be shown in yellow or green on a black field background. DIGITAL TABULAR DISPLAY MODULE TYPE TBOL TBO2 TBO3 TBO4 TBO5 TBO6 TBO7 TBO8 TBO9 TBLO TBLI TB12 TB13 TB14 TB15 TB16
IN OUT
TB17 TB18 TB19 TB20 TB21 TB22 TB23 TB24 TB25 TB26 TB27 TB28 TB29 TB30 TB31 TB32
F F F F F F F F F F F F F F F F
OUT
I/O ADDRESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
F F F F F F F F F F F F F F F F
TBOI TBO2 TBO3 TBO4 TBO5 TBO6 TBO7 TBO8 TBO9 TBIO TBll TB12 TB13 TB14 TB15 TBI6
1 2 0 4 0 0 0 0 0 0 0 0 0 0 0 0
1 F F F F F F F F F F F F F F F F
2 F F F F F F F F F F F F F F F F
3 F F F F F F F F F F F F F F F F
4 F F F F F F F F F F F F F F F F
5 F F F F F F F F F F F F F F F F
6 F F F F F F F F F F F F F F F F
7 F F F F F F F F F F F F F F F F
8 F F F F F F F F F F F F F F F F
9 F F F F F F F F F F F F F F F F
10 F F F F F F F F F F F F F F F F
11 F F F F F F F F F F F F F F F F
12 F F F F F F F F F F F F F F F F
13 F F F F F F F F F F F F F F F F
14 F F F F F F F F F F F F F F F F
15 F F F F F F F F F F F F F F F F
16 F F F F F F F F F F F F F F F F
TBI7 TB18 TB19 TB20 TB21 TB22 TB23 TB24 TB25 TB26 TB27 TB28 TB29 TB30 TB31 TB32
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Figure 7-6. Interaction Page 13, Digital Tabular Display.
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Chapter 8 Alarms and Diagnostics Annunciation of Alarms Diagnostic alarms originating at a DPU are posted as remote alarms on the maxSTATION Alarm List. Refer to Publication 277558, Alarm Message Reference Guide, for a description of these alarms. DPU front panel LEDs also indicate certain fatal diagnostic alarms.
Front Panel Numeric LEDs During normal operation, the numeric LEDs reflect the activity of the DPU Bus Card). If a DPU is reset, it initially displays 88; during its restart cycle, it displays FF, progresses through a series of steps counting down from 0F to 06, then goes online. Once online, a healthy DPU typically displays a rapidly flickering number whose value is predominantly 07. If a DPU is disconnected from the data DPU Bus, it displays a steady value of 07. If a DPU has a failure which prevents the DPU Bus Card from working properly, the DPU will drop off the data DPU Bus. Front panel LEDs will then be used to display two diagnostic codes alternating every 1.5 seconds, one reflecting the condition detected by the DPU Bus Card, and the other reflecting the highest priority alarm reported by any of the processors. The DPU Bus Card reports the following detected conditions: DA
The DPU Bus address set on the front-panel rotary switches is illegal (e.g., 00).
DC
Jabberhalt timeout; the DPU Bus Card transmitted on the DPU Bus too long.
DF
The DPU Bus Card either detected a stack imbalance or executed an illegal instruction.
The alarm code alternating with one of the above DPU Bus Card codes may be any of the alarm codes listed in the Alarm Message Reference Guide. In most cases, the two codes are independent; in a few special cases, one may be the cause of the other. The most likely of those special cases is DC (jabberhalt) combined with one of the following:
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