metso automation PDP 400 maxDPU4F Series, Hardware Manual

Page 1: ...Model PDP Series 400 maxDPU4F Hardware Guide 278705 Rev A3 ...

Page 2: ...u better operate and service Metso Automation equipment Your comments and suggestions are welcome Metso Automation 1180 Church Road Lansdale PA 19446 Attention Manager Technical Publications Copyright 2005 by Metso Automation MAX Controls Inc Printed in the United States of America All rights reserved ...

Page 3: ...U 1 3 Positioning the DPU in a Standard maxPAC Chassis 1 3 Positioning the DPU When Upgrading 1 4 Mounting Procedures 1 4 DPU Front Panel Controls and Features 1 4 Mode Switch 1 5 maxNET Interface Ports 1 5 Network Status LEDs 1 5 Backup Port 1 5 Backup LED 1 5 Serial Port Optional 1 5 Reset Button 1 5 IOM Status LED 1 5 I O Status LED 1 6 CP Status LED 1 6 State LED 1 6 Takeover Button 1 6 IRIG B...

Page 4: ... Installing Windows CE and maxDNA Software onto the DPU CompactFlash Memory 5 1 Overview 5 1 Writing the CompactFlash Using the DPU4FSetup Utility 5 1 CHAPTER 6 6 1 Redundant DPU Operation 6 1 Overview 6 1 Automatic Failover Manual Takeover 6 1 Automatic Failover 6 1 Manual Takeover 6 1 Backup State Definition 6 2 CHAPTER 7 7 1 Starting the DPU 7 1 Demanding a Blank Startup 7 1 Starting a Standalo...

Page 5: ...perate 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 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 millise...

Page 6: ...ed 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 I O Bus Interface A Motorola 68332 32 bit I O processor and field programmable gate array FPGA ...

Page 7: ...uts 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 noncond...

Page 8: ...d in the back panel metal frame If the previous DPU was a DPU4E the Ethernet cables that were plugged into the termination panel can be plugged directly into the front panel of the DPU card Make sure that the settings of the Ethernet switch match the setup file See Chapter 5 for the configuration setup If the previous DPU was a DPU3 DPU4A or DPU4B new Ethernet switches and cables will need to be i...

Page 9: ...s report the status of maxNET Network A and B links Backup Port A 100 MB Ethernet interface is provided to pass database information to a hot standby DPU A custom Category 5 Ethernet cable Part 050292 is used to connect both DPUs via this port A status signals are also passed between DPUs through this port to indicate which DPU is in control Backup LED This LED shows the status of redundancy for D...

Page 10: ...over Button Pressing the Takeover button can force a previously inactive DPU to go active This should not be done casually as a manually forced takeover occurs regardless of the inactive DPU s ability to control This can have severe consequences to your process Refer to Chapter 3 for more detailed information on the use of this button IRIG B Port Optional The IRIG port is a BNC connector that supp...

Page 11: ...essor will not affect the operation of the other or cause a DPU failover Ethernet messages are sent received based upon the DPU s Ethernet address with minimal control processor intervention Configuring the Ethernet Switch Each DPU connects to the maxNET through two Ethernet switches one for Network A and one for Network B The Ethernet switch ports that connect to DPUs should be configured for 10M...

Page 12: ...2 The serial port supports redundancy when a backup pair of DPUs is used The serial port is only operational if the DPU is Active The RS232 drivers on the Inactive DPU are turned off The use of this feature requires a redundancy cable to connect between the two DPUs and the RS232 device Metso Automation 050355 This cable has an RJ45 for each DPU and a common DB9 connector with male pins Table 2 1 ...

Page 13: ...tory personnel use Setting Normal Use Description 0 X On line operation but Locked which inhibits database changes 1 X Off line operation In this mode the outputs are Frozen and therefore will not change The State LED will be red The mode switch can be changed from 1 and back to F without resetting the DPU 2 reserved 3 reserved 4 reserved 5 reserved 6 reserved 7 reserved 8 Advanced Operational Mod...

Page 14: ...set NOTE during normal operation the DPU continually saves the configuration database to CompactFlash For typical databases this will be done every 5 minutes If a hard reset is performed the DPU will still contain a recent database and will attempt control once restored This is different from previous versions of the DPU where the configuration database was not routinely saved In previous DPUs a H...

Page 15: ... When the inactive DPU becomes hot it will automatically go active if the active DPU s quality is significantly below the quality of the inactive DPU If you wish to guarantee that an inactive DPU goes active and stays active you must kill the currently active DPU This can be done by either unplugging the DPU from its chassis or by writing to the ForceFatal attribute of the active DPU Pressing the ...

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Page 17: ...Ds maxNET Network A health 1 Green and 1 Yellow maxNET Network B health 1 Green and 1 Yellow Backup link health 1 Multicolor Green Red Yellow Operational Status LEDs IOM Health 1 Multicolor Green Red Yellow I O Status 1 Multicolor Green Red Yellow CP Health 1 Multicolor Green Red Yellow State 1 Multicolor Green Red Yellow All or some of the LEDs display a set of color codes associated with the fol...

Page 18: ... DO NOT stop the DPU during this period or the flash could become corrupt and the DPU will need to be returned to the factory for repair Once the BIOS is written the DPU will go through another reset cycle Most updates will not require a BIOS change Next the CP goes yellow while rebuilding the database This can be brief or up to 30 seconds depending on the size of the stored database The CP LED th...

Page 19: ...d to Backup DPU DPU not Operational or LED Bad IOM Operational IOM N A IOM Failed Timed out Reset Required IOM not initialized I O All configured I O cards are working correctly Some configured I O cards are working correctly some are not No configured I O cards are working correctly No I O cards configured in the database or IOM failure CP Blink Yellow Green Healthy Heartbeat Solid Green CP failu...

Page 20: ...fferent types or different applications are assigned to different queues The following table shows the queue assignments for each type or application of an I O module I O Card DI LED AO DO LED AI LED Unlabeled LED Item Queue SOE DI X Slow DI X AI 564 X TC 564 X RTD 564 X AO 564 X Counter Timer 564 X Quad PAT 564 or maxPAC X X Output Driver 564 X DO 564 or maxPAC X AI maxPAC X X TC maxPAC X X RTD m...

Page 21: ...rocessor s CE Windows operating system and application firmware Input Output Manager IOM Flash Firmware Configuration File for Shared Memory FPGA Configuration File for IO FPGA IOM Diagnostic Code Firmware BIOS Embedded BIOS code Initialization file containing DPU Name IP Address and general configuration information From time to time the DPU will need to be upgraded to receive the latest firmware...

Page 22: ...onnected to a USB port of the maxSTATION while the DPU is not installed in a chassis Detailed instructions on performing these updates can be found by running the DPU4FSetup program and clicking on the at the top of the dialog To run the DPU4FSetup Utility select Start AllPrograms maxDNA maxDPU Utilities DPU4FSetup ...

Page 23: ...keover 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 second...

Page 24: ... and or Net B functional outage of one for more than 5 minutes IO Errors above threshold while some IO good Pulse Faults Time Errors 3 Serious Errors will only run if necessary Net A and Net B both non functional Database out of date IOM_Diag_Errors All IO Bad 4 Fatal Errors cannot run regardless The following table represents which DPU will be the Active DPU based on the backup health state Curre...

Page 25: ...nce 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 m...

Page 26: ...actFlash This utility will configure the IP Address Redundancy select StandAlone Network Speed Duplex and Version of Software Reinstall the CompactFlash in the DPU Note if you select Primary instead of StandAlone the DPU will not be able to go into the online state unless a backup cable is installed 2 Set front panel mode switches to B to demand a Cold startup 3 Insert the DPU into the chassis slo...

Page 27: ... secondary Select Secondary 2 Set the Primary DPU Mode Switch to B to demand a Cold startup 3 Insert the Primary DPU into the chassis slot but not far enough to make contact with the back plane connector 4 Insert the A network cable into the top RJ45 connector and if available the B network cable into the second RJ45 connector 5 Insert the Backup network cable into the backup connector NOTE If the...

Page 28: ...go to their new computed values 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 the DPU that is to remain in pl...

Page 29: ...ional 12 Set the Mode Switch to F 13 Once the DPU has warmed the following are the expected states of the LEDs A Network Green B Network Green if dual network and off if single network Backup Green IOM Green I O Green if any Redundant I O defined Off if no Redundant I O CP Blinking Green Yellow State blinking Yellow Off 14 Acknowledge all alarms from the new DPU and make sure they clear Restarting...

Page 30: ...ve If it does not properly warm it should be replaced Alarm Annunciation Diagnostic alarms originating at a DPU are posted as remote alarms on the maxSTATION Alarm List Refer to Publication 278558 Alarm Message Reference Guide for a description of these alarms DPU front panel LEDs also indicate certain fatal diagnostic alarms ...

Page 31: ...de the signal Once it decodes the signal the DPU uses it as the basis for its internal clock Normally the IRIG DPU is assigned the roll of a Time Master via a database setting and it broadcasts the accurate time to the rest of the DPUs DBMs and direct access workstations in its domain In this way the entire domain can be synchronized to an accurate clock The IRIG signal should be applied to both t...

Page 32: ... other noisy signals To reduce the likelihood of noise pickup do not run the IRIG cable parallel to noisy wires Since the IRIG input on the DPU is high impedance and the IRIG sources have low output impedance typically 50 or 600 ohms the signal may be applied in parallel to multiple DPUs via BNC T or Y connectors However if that single cable is damaged all of the parallel wired DPUs could lose the...