Transcript IO Maintenance

MODULE ONE
I/O MAINTENANCE
•
i/o SUBSYSTEM
I/O Alarms and Diagnostics
When something unexpected happens, the maxDNA System will
usually post an alarm in the Alarm Summary and possibly sound an
annunciator if the failing point has been configured to do so. View
the Alarm S ummary Display and determine what type of error
occurred and whatelement was involved.
Distributed Processing Unit Functionality
The Model PDP Distributed Processing Unit (DPU) which runs under
the Windows CE realtime multitasking, operating system, is the
hardware processing engine of the maxDNA distributed control
system.The DPU performs primary data acquisition, control, and
data processing functions.
© Metso Automation Inc. 2005
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The DPU is a self-contained microprocessor-based, rack-mounted unit,
which occupies either a single slot in a Remote Processing Unit cabinet
using a 4-wide backplane or one or two slots when using a 6-wide or 8wide maxPAC backplane. 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 maxNET, 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 at 1 millisecond
resolution.
·
Acquisition of trend information.
·
Continuous scanning of Model IOP I/O modules.
·
Execution of predefined algorithms called Atoms and buffers for
process control and data acquisition.
© Metso Automation Inc. 2005
Distributed Processing Unit Hardware
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•
A DPU consists of a printed circuit board containing the Control Processor
and Input/Output Processor (IOP) attached to a DPU chassis (4E). The
DPU’s front panel contains status LEDs, and takeover and reset buttons,
while the DPU’s front chassis panel (4E) contains network, backup and
serial port connectors, mode and network address switches, and the key
switch.
Control Processor
The DPU itself consists of a main board and a Control
Processor daughter card known as the Intel Embedded Pentium
Processor Module. The Control Processor interfaces with 32
MByte DRAM (minimum), a PCI Bus, and 8 MByte Flash
memory.
Performance
A multispeed processing system is built into the maxDPU4E,
which allows objects to be executed in four different time
classes. From as fast as 20 msec to 1 second. Up to 6,000
control objects (atoms) can be executed in the DPU. Note also that
Function Blocks can be combined to create libraries of
Standard and Custom Blocks. A Function Block can be as small
as an Atomic Block, such as an AND or OR gate.
A data point management system (DPMS) keeps track of the
object size and the total execution time for each time class.
© Metso Automation Inc. 2005
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I/O Bus Interface
A Motorola 68332 32-bit I/O processor and field programmable gate array
(FPGA) are used to interface to both the Model IOP I/O bus and to the I/O
Bus Expander Module (BEM) for remote I/O applications. Up to 60 Model
IOP I/O modules can reside on the bus. The maximum length of the Model
564 I/O bus is 30 ft. The length of the remote I/O link with fiber optic
extenders is up to 2000 m.
© Metso Automation Inc. 2005
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Fully Self Describing Object Oriented Database
All information regarding the operation of the DPU is kept in DPU memory,
including: tag names, descriptions, tuning constants, alarm limits, etc. in
addition, all graphical configuration data (sheet number, object location,
wiring) is stored in the DPU.
This means that there is no possibility that the configuration observed is
different than that which is installed in the DPU.
Objects are stored in a fully hierarchical database, allowing for easy cut
and paste changes and protection of control strategies.
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Fully MCS Software Backplane Compliant
With the MCS software backplane installed, the DPU can access any
exposed data stored anywhere in a connected system as long as the
connected system also uses the SPB Protocol. Peer-to-peer transfers are
rapid and transparent. No independent transfer agent is required.
The Software Backplane uses subscription services where data is only
transmitted when changes are detected.
© Metso Automation Inc. 2005
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Sequence of Events
Each DPU includes a built-in Sequence-of-Events (SOE) recorder that can
monitor up to 500 discrete inputs. These inputs are scanned 1,000 times a
second and state changes are time stamped with 1 ms resolution and
stored in the DPU's 10,000 event buffer. Each input has a separately
configurable digital filter for contact debounce.
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
Current:
1.2 A @ 24 Vdc
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Powering the DPU
The DPU operates from the main redundant 24 Vdc power supply system
in the maxDNA system cabinets.
Onboard DC/DC regulators provide 5 V and 3.3 V power for the card.
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Mounting the DPU
The DPU is mounted on the Input/Output (I/O) backplane with Model IOP
Input/Output modules.
© Metso Automation Inc. 2005
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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 or 8-wide maxPAC I/O rack, the mounting bracket to the left of the
DPU must be removed since the DPU requires a DPU chassis to be
mounted in this slot location.
When using a second DPU for backup, it should be mounted vertically
beneath the primary DPU for ease of connection of the two-foot backup
cable.
© Metso Automation Inc. 2005
maxDPU4F
DPU4F Functionality
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The new DPU4F design changed the CP and was designed and based on
the National Geode® processor. The card is now faster and equipped to
handle more RAM. Although the CP has changed, the IOM and
564/macPAC interfaces were based on the DPU4E design. The I/O bus
interface was implemented with a Motorola 68332 processor and Altera
FPGA with look up table RAM. Another FPGA is used to control bus
arbitration between the Geode and 68332 to shared memory. The Geode
gains access to the shared memory and IOM via a PCI interface chip.
There are four other devices besides the Geode that reside on the PCI
bus; three Ethernet chips (Net A,B and Backup) and the PCI chip.
•
The hardware components can now be initialized using a compact flash
media. Windows CE will also be featured in this compact flash which will
also contain additional application software for the DPU4F.
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The DPU4F will be able to interface with a 564/maxPAC bus. The DPU4E
“fingers” will be eliminated, which will allow the DPU4F to be inserted into a
macPAC chassis without losing its ability to be inserted into a DPU4E
chassis. An existing screw-on slot formerly used for BEM will be used to
field retrofit a DPU4F into a 564 type chassis.
© Metso Automation Inc. 2005
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DPU4F Hardware Overview
The block diagram of the DPU4F showing all the major electrical
components is shown in Figure. The diagram gives a layout of all the major
components in the card. The black lines with arrows indicate a connection
between components. The wide arrows between components represent
busses. Notice that the Geode processor is directly connected to the
compact flash, which contains CE and DPMS. The compact flash is
connected by an IDE bus. On power up, the CP will load the CE operating
system and run programs like DPMS, maxRRS and maxTransport.
While the DPU4F is initializing, the CP will load software configuration from
the compact flash into the two FPGAs. The PCI chip will help to transmit
the configuration file into the FPGAs. The bus arbitration FPGA is
connected to both the PCI chip and the Motorolla 68332. Since both the
Geode and 68332 are trying get information from the shared memory, the
FPGA decides which of the two processors has access to the memory. The
I/O FPGA is connected to the look-up table RAM as well as the 68332.
This chip controls the interface between the I/O and 68332 processor.
Connected to the PCI bus are three National Ethernet chips. The DPU4F
will be able to support two Ethernet networks that can operate at 10 or 100
Mbps full duplex. It will also support a 100 Mbps Ethernet connection for
the backup link.
© Metso Automation Inc. 2005
DPU4F Hardware Overview
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The DPU4F also has a programmable CPLD chip. It helps control which of
the Ethernet ports has access to the PCI bus. There is also logic to stop
any I/O and backup communications based on low voltage or memory
errors. The CPLD also determines whether the board boots from a fixed
flash or a socketed flash. The CPLD has changed a great deal compared
to the 4E. Most of the logic in the 4E’s CPLD has been moved to the
FPGA.
•
The compact flash contains files for the CE platform and other MAX
programs. The flash also contains a BIOS file and configuration files for the
two FPGAs and 68332 chip. Diagnostic files are also included to help
troubleshoot the card and verify operations.
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The DPU4F has four discrete power supplies built onto the card itself.
From the 24VDC input, the board uses it to generate a bulk voltage of 14V.
Once the VBULK is stabilized, the board will enable the 2V, 3.3V and 5V
supplies. The three and five volt supplies will feed the multitude of
components with three and five volt logic respectively. The three volt
components and logic are located towards the left of the PCI chip. The five
volt components and logic are located towards the right of the PCI chip.
The PCI chip acts like a bride between these voltage and logic levels. The
two volt supply is only used to power the Geode processor.
© Metso Automation Inc. 2005
maxDPU4F Block Diagram
National
Takeover
S3
IRIG
IRIG
BNC
+
+
-
+
U9 , U1 0
IRIG
Analog
Front
End
J3
SDRAM
SODIMM
Amp socket
390113
(144 pin)
GEODE
JTAG
S u p p o rt
J 10
IOM Serial
Debug Port
Super Cap
3V
USB Parts
J 15
J9
Connector
Pin 1
Rev. 29
J 19
S u p p o rt
k e e p o u t a re a
Dowser
© Metso Automation Inc. 2005
-
-
Serial
Prom
-
J8
+
D6
(97)
-
D5
Tem p
CPLD
JTAG
+
CP
State
4
LEDs
and
Light
Pipes
PAGE 16 to
see what is
included
(See DPU4E
for placement)
RP
U1 2
1
D4
+
U2 0
1
IO
U2
U8
+
D3
564 Bus
Interface
B u ff e r
-
(4)
RS232
Dvr/Rcv
IOM
(24)
RP
(432 pin BGA)
U7
(4)
S2
S u p p o rt
-
Reset
U2 5
U3 5
CPLD
(44pin)
J2
(144 Pin)
(208 pin)
Geode
Processor
SC2200
PS
Filters
U1 3
Tx
RJ45
PS Filter
PCI Bus
Clk
DVR
5V
I/O Bus
Interface
FPGA
+
Xfmr
T1
Rx
(27)
U8
68332
CPU
+
S u p p o rt
(35)
IDE
27 MHz
32.768 KHz
Xtals
-
2 LEDs
+ Light
Pipes
+
D2
(40)
DP83816
QFP 144 pin
Ethernet
(4)
D1
SHARED
RAM U29
L a tc h
U2 1
-
L a tc h
U1 9
J1
Backup
Serial
Port
+
U2 4
RJ45
LUT
RAM
U34
(208 pin)
+
U1 8
U6
Backup
SHARED
RAM U28
-
(38)
(40)
+
(176 Pin)
Bus
Arbitration
FPGA
1
DP83816
QFP 144 pin
Ethernet
-
National
(4)
J5
1
B
RP
+
Network
PCI
Interface
Chip
S u p p o rt
J 16
IDE
Clk
DVR
(56)
RJ45
+xfmr
25 MHz
Osc.
+
1
Clk
DVR
U5
+
-
(4)
J4
+
C
DP83816
QFP 144 pin
Ethernet
PS
Comps.
-
A
National
Amp Socket
788667
(50 pin)
+
RJ45
+xfmr
Network
J 12
J 13
Compact Flash
1
1
ISA Bus
Resistors
PCI Debug
Connector
-
-
-
Mode
(28)
+
+
1
1
P
O
L
A
R
I
S
J 14
U1 1
U4
S1
Vbulk
BIOS
Flash
Test Socket
for FLASH
C
Ba c k u p
L in k
M IS C.
S u p p o rt
DPU4F
Video
Parts
USB X 2
+Comm 1
+Video
J 20
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The DPU4F has a 1.5F capacitor that has the ability to power a real time
clock (RTC) when the DPU is not powered. It can power a RTC up to 24
hours. The DPU4F also support an IRIG-B interface for external time
syncing. The IRIG signal coming into the DPU4F will be transformer
coupled on-board. The amplitude modulated signal is the only standard
supported by the DPUs.
•
Similar to the DPU4E, process control can be transferred automatically or
manually with a simple takeover switch. This switch is located on the front
panel of the DPU4F. The backup Ethernet cable must be plugged into both
primary and secondary DPUs. The cable will carry data signals as well as
status signals to determine which of the DPUs is active. Please see the
section, Bringing up the DPU4F, for further details about signals involved in
failover.
•
The DPU4F was engineered to operate under a wide range of
environmental conditions. The operating temperature can range from 0 to
60 degrees Celsius. The operating relative humidity range is from 5 to 90%
non-condensing.
© Metso Automation Inc. 2005
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DPU4F Software Overview
In the new DPU4F platform, there have been a few software upgrades and
additions to complement the DPU4F. Due to Microsoft’s new line of .NET
products, Metso has decided to support their changes and upgrades. The
prior CE environment has been upgraded to CE.NET. The new .NET
framework has the ability to support a web server on the DPU4Fs. For
example, the user can now view the file contents and information of the
DPU through a web browser. It is intended that basic DPMS statistics can
be viewed by the web browser. Simply enter the DPU’s IP address in the
address screen and the user will view a screen similar to that below.
© Metso Automation Inc. 2005
Windows CE Display
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Some new components have been added to the DPU4F. There is now an
IOM monitoring atom that will alarm on any IOM failures. There is also a
new temperature atom that can monitor the temperature of the CP. Larger
databases and more structures can now be supported by the DPU4F. Most
of the new features will be implemented and can be seen in MaxVUE
under the DPU4F Summary or DPU4F Details display. Please note that the
majority of DPU4E features have been passed along to this new line.
•
The DPU4F has also added a new identifying feature. An EEprom will be
included that will contain a unique serial and board revision number.
•
A compact flash configuration tool has been created to easily update a
compact flash with the necessary system files. Originally, the user had to
manually copy files into the compact flash. This utility has provided a safer
and more efficient way to update or add system files to a flash.
•
The DPU4F has now been designed to make troubleshooting easier on the
user. Besides from the on-board video, it now has built-in diagnostic
programs. The user can now simply connect a monitor, keyboard and
mouse to the DPU and run the diagnostic programs with the flip of a mode
switch.
© Metso Automation Inc. 2005
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DPU4F Compact Flash (CF) Setup
Before running the DPU, the user must make sure the correct configuration
and DPU files are loaded into the compact flash. There are (7) necessary
files:







File Names
config.ini
nk.bin
iom4f.s3m
iom4diag1.s3m
iom.rbf
shmem.rbf
merged.rom
© Metso Automation Inc. 2005
Desciption
Configuration file for DPU. Contains IP & MAC address,
DPU Name
Image file containing CP Code
Instruction Code for the IOM
File containing the diagnostic for IOM
Configuration file of the IOM FPGA.
Configuration file of the shared memory FPGA.
System Bios File
The following are the steps needed to configure the compact flash.
1. Insert the compact flash into the reader
2. Run the program DPU4FSetup clicking either on a desk to Icon or
navigating to Start-All Programs-maxDNA-maxDPU Utilities-DPU4Fsetup.
3. The first screen shown below is for setting up the basic configuration of
the DPU:
© Metso Automation Inc. 2005
DPU4F Setup Dialog Box
4. If the Compact Flash was previously programmed, Click the Read Flash
Card button to import the previous .ini file. (NOTE: If the computer has
more than one removable disk drive, go to the Flash Card tab and select
the proper drive letter before clicking on the Read Flash Card button) Verify
that the configuration information is correct. If this is a new configuration
then enter the following information:
-
Use the pull-down menu to select the DPU or enter the name of the
DPU (the pull-down list is retrieved from the DPULIST.ini.)
-
Enter the IP address of the DPU
-
Select the Redundancy options. Notice that Stand Alone (single DPU)
and Primary DPUs are always even addresses and Secondary DPUs
are always odd addresses. The utility will automatically change the
address field to match the redundancy selection.
-
Select Net Speed. This selection must match the settings of the
Ethernet Switch for that DPU. For proper system performance the DPU
communications must be full duplex.
© Metso Automation Inc. 2005
5. Most systems will have dual networks. Uncheck the Dual Network box
ONLY if you have one network. This will prevent network alarms if the “B”
Network is not operational.
6. Click on the software tab to select the version of software to be written to
the CompactFlash. Use the pull-down menu to select the version of
software used in the DPUs. This selection will automatically select the
proper files to be loaded. There is a manual selection available. This
should only be used under special circumstances under direction from
Metso.
DPU4F Setup Software Tab
© Metso Automation Inc. 2005
7. Click on the tab labeled, Flash Card. The screen will look like the following:
DPU4F Setup Flash Tab
© Metso Automation Inc. 2005
8. The setup utility will automatically detect removable disk drives
connected to this computer. If the proper drive letter is not shown, use the
pull-down menu to select the proper drive letter.
9. If the DPU is being upgraded, it is best to erase any configuration
databases from the compact flash. Only uncheck the “Erase Database”
box when the configuration database must be preserved and the new
release has the same file format as the previous release. A new
CompactFlash will not contain any Database files so it does not matter
whether this box is checked.
10. Verify that the DPU Name and DPU IP are correct and click on “Make
Flash”. There will be a pop-up showing the progress as the files are
written. When complete, there will be a pop-up stating that the Operation
is Complete and that the flash media can be removed.
© Metso Automation Inc. 2005
Figure 3.1. - DPU4F Setup Successful Completion Indicator
11. The utility program automatically performs a Windows “Eject”
command, so the CompactFlash can safely be removed from the Reader.
12. Insert the CompactFlash in the socket at the top of the DPU4F.
© Metso Automation Inc. 2005
Led Definitions
LED
Green
Network A
Network A is
operational
Network B
Network B is
operational
Net Backup
Backup network is
operational
Some backup
network failures
Communications
DPU not operational
not established
or LED is bad
to backup DPU
IOM
IOM is operational
N/A
IOM Failed/
Timed out
I/O
All configured cards Some configured
are working properly cards are working
properly and
some are not
CP
State
© Metso Automation Inc. 2005
Yellow
Some network A
failures Blinking
Yellow network
failure.
Some network B
failures Blinking
Yellow network
failure.
Red
Off
N/A
DPU not operational
or LED is bad
N/A
DPU not operational
or LED is bad
IOM is not
initialized
No cards are
No configured
configured in the
cards are
database or IOM
working properly
failed
Blinking Yellow/
Green – Healthy
Heartbeat
Solid Yellow –
Booting, Loading
or saving the
N/A
database, or
CP failure
Card Failure
See Table Below
See Table Below
Booting or In
diagnostic mode
See Table Below
DPU States
Standalone DPUs
Backup Warming
Hot Backup
Backup Enabled No Backup
Available
Offline
Booting
Active DPU State/LED
Green
Blinking Green/Red
Blinking Green/Yellow
Blinking Green/Off
Inactive DPU State/LED
Yellow
Blinking Yellow/Red
Blinking Yellow/Off
N/A
Red
Off then Blinking Red
Red
Off then Blinking Red
DPU4F State Indicator Definitions
© Metso Automation Inc. 2005
•
Redundant DPU Operation
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 IP address of the secondary DPU is always one
number greater than the address of the primary DPU. The primary is
always the even address while the Secondary is the odd address
The installation, preparation, and adjustment procedures included in this
publication apply to both DPUs in a redundant configuration.
• Automatic Failover / Manual Takeover
Process control can be transferred automatically (Failover), or can be
manually commanded to takeover. Automatic Failover can occur from
either the primary DPU to the secondary DPU or from the secondary to
primary based on the health of each DPU.
• 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.
• 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 only if the
inactive DPU is healthy enough to assume control. If a severe diagnostic
alarm or a fatal alarm condition exists in the inactive DPU then the
© Metso Automation Inc. 2005
Takeover button will be ignored.
Starting the DPU
•
Startup States
When a DPU is first powered, it checks for a valid configuration and
database existing in its flash memory and proceeds to load it. The DPU
then listens over the backup link to see if another DPU is active and in
control before it operates on the loaded configuration.
•
If no backup DPU is present (no backup link communications, no Network
A/B Communications, no Active Pulses on the backup link cable) then, the
DPU continues to operate with its loaded configuration and intended
operation as either a Standalone DPU or a Backup DPU. It becomes the
Active DPU since no other DPU is in control.
•
If a backup DPU is present then, this DPU listens to the other DPU over
the backup link as to its current operation as Standalone or Redundant
DPU. If the other active DPU is set as a Redundant DPU (NOT
Standalone) then, this inactive DPU will erase its configuration/database
and proceed to gather configuration and database information over the
backup link. This DPU will move from an empty state to a Warming State
and then to a Hot Standby State and becomes ready to assume control
when commanded to take over.
© Metso Automation Inc. 2005
Demanding a Blank Startup
•
When a DPU is first placed in service 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 the Mode switch to ‘B’ on the DPU
Chassis. After the DPU has gone through its startup sequence as
described in "Starting a Standalone DPU," be sure to set the Mode switch
back to ‘F’ to prevent future Cold startups.
© Metso Automation Inc. 2005
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:
1.
Turn the DPU key switch to the Off-line position (fully
counter-clockwise).
2.
Set front panel mode switches to “B” to demand a Cold startup, as
described in the preceding section if necessary.
3.
Verify that the NiCd battery pack is plugged in and passing Battery
test (Battery LED is green.)
4.
Verify the proper IP Address is set in the Network Address switches.
5.
Position the DPU into the top and bottom card guides of the chassis.
6.
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.
© Metso Automation Inc. 2005
7.
8.
9.
10.
11.
12.
13.
14.
15.
When the contacts are engaged and resistance is felt, firmly press
on the front panel of the DPU’s 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.
Secure module to chassis assembly with the top and bottom lock
down screws on the front of the module.
Verify that the NiCd battery pack is plugged in and passing Battery
test (Battery LED is green.)
Return Mode Switch to “F”.
Verify the DPU shows up as healthy in the HealthLog List.
Reload the DPU using the DPU4E Download Program from the
maxSTATION.
Acknowledge all alarms from the DPU and make sure that they all
clear.
Utilize the Unfreeze feature to allow all or selective outputs to
transition to their new computed values.
Place the key switch in the Run or Locked mode.
© Metso Automation Inc. 2005
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 key switches to the Off-line position (fully
counter clockwise).
2.
On each DPU, set Mode switch to “F”for Normal Operation.
3.
Verify that the NiCd battery pack is plugged in and passing Battery
test (Battery LED is green.)
4.
Verify the proper IP address is set in the Network Addresses
switches.
5.
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.
6.
Verify backup cable is connected between both DPU chassis
7.
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.
© Metso Automation Inc. 2005
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
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.
Secure module to chassis assembly with the top and bottom lock
down screws on the front of the module.
Verify that the NiCd battery pack is plugged in and passing Battery
test (Battery LED is green.)
Reload the primary DPU using the maxSTATION.
Acknowledge all alarms from the primary DPU.
Place the key switch of the primary DPU in the Run or Locked mode.
Insert the secondary card using the same steps as the primary.
Make sure the secondary starts up and begins communicating on
the maxNET as described above.
Verify DPU shows up as healthy in the Health Log List
Acknowledge all alarms from the DPU pair and make sure that
secondary alarms are all clear.
Make sure that the primary DPU is displaying the alarm Backup Link
Timeout to make sure there are no higher priority alarms.
Place the key switch of the secondary DPU in the Run or Locked
mode.
Acknowledge all DPU alarms and make sure they all clear.
© Metso Automation Inc. 2005
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 if it is
not Active and verify it properly assumes control of the process.
2.
Turn the key switch of the DPU being replaced to the Off-line
position (fully counter-clockwise).
3.
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 60 seconds if the DPU failed in a fatal state.
4.
On the new DPU, verify that the NiCd battery pack is plugged in
correctly to the motherboard connector.
5.
Replace the DPU with the new unit by positioning the new DPU into
the top and bottom card guides of the chassis, but DO NOT push the
new unit in far enough to apply power to it.
6.
Set Mode switch to “B”if necessary to demand a Blank startup.
7.
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.
© Metso Automation Inc. 2005
8.
9.
10.
11.
12.
13.
14.
15.
16.
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.
Secure module to chassis assembly with the top and bottom lock
down screws on the front of the module.
Return Mode switch to “F” if necessary.
Verify DPU progresses from BLANK State to Warming to Hot
Standby via LED State and via Backup Atom attributes as viewed
from the Point Browser at the maxSTATION.
Acknowledge all alarms from the new DPU.
Place the key switch of the new DPU in the Run or Locked mode.
If the new DPU is the primary of the pair, wait at least 30 seconds to
allow its configuration and database to be updated, then press its
Takeover button to give it control.
Acknowledge all DPU alarms and make sure they all clear.
If the DPU is to be shipped or put in storage, unplug the NiCd battery
pack from the motherboard’s connector.
© Metso Automation Inc. 2005
Annunciation of Alarms
Diagnostic alarms originating at a DPU are posted as remote alarms
on the maxSTATION Alarm List. DPU front panel LEDs also indicate
certain fatal diagnostic alarms.
Interpreting DPU
Diagnostics
This area provides information on DPU diagnostics running both at startup
and during normal operation.
•
Core Processor Diagnostics
During Startup the CP performs the following tests
· BIOS checksum test
· BIOS POST Tests including DRAM Memory test
· CE Integrity test of executable code via checksum test
· Configuration Database checksum test
· IP Address change test
· DPRAM integrity test
· Power supplies level checks
© Metso Automation Inc. 2005
During normal operation the CP performs the following tests
·
Battery tests
·
DRAM parity errors
·
Watch dog tests
·
Memory integrity tests
·
Active Pulse frequency check
•
IOM Processor Diagnostics
During Startup the IOM performs the following tests
·
Flash checksum test
·
FPGA configuration test
·
DPRAM integrity test
·
FPGA RAM integrity test
·
IO Bus integrity test
During normal operation the IOM performs the following tests
·
Flash checksum test
·
IO Bus diagnostics on inactive DPU
·
Watch dog tests
© Metso Automation Inc. 2005
Setting DPU and maxSTATION Time
•
Time Set Program
This program allows propagation of the Workstation time to DPUs or
other Workstations. The program can be found in
c:\mcs\spb\MCSTimeSet.exe.
MCSTime Set Dialog Box.
© Metso Automation Inc. 2005
The Current UTC Date/Time is read from the NT real time clock. If this
needs to be changed, use the normal NT time set functions for the
workstation.
The program can set either a single station or a list of stations. The
following are options for which stations to set.
“[172.16.4.3]” will set only that workstation or DPU.
“NT” will set all of the stations listed in c:\custom\database\workgroup.ini
“DPU” will set all of the DPUs listed in c:\custom\database\dpulist.ini
“ALL” will set all DPUs and Workstations listed in the above ini files.
Click on the Set Time button to update the time of each device to the time
shown in the Current UTC Date/Time field. The View Tally is an option to
view the results of the operation. The status of the time set to each of the
stations and the amount of time adjustment is included in the tally. The
following is a sample of the tally output. The times are in seconds.
© Metso Automation Inc. 2005
DPU Battery and Fuse Maintenance
Replacing DPU Fuses
To replace any one of the two fuses:
1.
Important: If the DPU to be serviced is part of a DPU pair, use the
instructions in Chapter X, "Replacing a DPU in a Backup Pair" to
extract the DPU. If the DPU to be serviced is configured as
standalone, place the key switch in the offline position and use the
following instructions.
2.
Gently slide the DPU module out of the cabinet rack and set the unit
down on an appropriate work surface, component side up.
3.
Locate the battery compartment on the upper right side and remove
the battery plug from the J13 connector.
4.
Remove the top metal cover.
5.
Locate the fuse to be replaced. Both fuses are located on the upper
right side of the motherboard.
6.
Carefully remove the fuse by pulling it straight up. Do not place any
pressure on the circuits near the fuse.
7.
Install the fuse into the same connector from which the old fuse was
removed.
8.
Install the metal cover.
9.
Reconnect the battery plug to J13 connector.
10. Install the DPU in the chassis using the appropriate procedure found
in earlier in this document," Starting a Standalone DPU," or
"Replacing a DPU in a Backup Pair.”
© Metso Automation Inc. 2005
I/O Faults
If any type of I/O fault is detected by the system, an alarm will be posted
and you will be given a "plain english" description of the fault and where it
occurred. An example of some typical I/O alarms can be found in the
Interpretation of Highway System Process Status & Alarms document and
in the diagram below.
© Metso Automation Inc. 2005
Alarm Summary Display.
Maintenance Logs
A maintenance log for the maxDNA System should be establish and
rigorously maintained. In it, you should document the following type of
maintenance information:
•
All hardware and software faults detected by the system
- A description of each fault
- Date and time of the fault
- Alarm information
- Error codes (for software faults)
- Other symptoms
•
A description of what caused the fault
•
A description of what action was taken to correct the fault
•
Initial of person making the entry
© Metso Automation Inc. 2005
END
© Metso Automation Inc. 2005