Metso PDP Series Installation, Preparation And Adjustment Download Page 1

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Model PDP DPU

Installation, Preparation

and Adjustment

277573 Rev. A1

Summary of Contents for PDP Series

Page 1: ...Model PDP DPU Installation Preparation and Adjustment 277573 Rev A1 ...

Page 2: ...operate and service Metso Automation MAX Controls equipment Your 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 ...

Page 3: ...e DPU 1 3 CHAPTER 2 2 1 DPU Front Panel 2 1 Overview 2 1 Mode Select DIP Switch Settings 2 1 Data Highway Area 2 2 Using Rotary Switches to Set Station Address 2 2 Two LED Displays 2 3 IOM Load 2 3 Status Section LEDs 2 4 DPU Hardware Status LEDs 2 4 Serial I O and DPU Status Section 2 4 Backup Status LEDs 2 5 Reset Button 2 6 Backup Link 2 6 CPU Load 2 6 Takeover Button 2 6 Backup DIP Switch Sett...

Page 4: ...g a Backup Pair of DPUs 6 3 Replacing a DPU in a Backup Pair 6 5 CHAPTER 7 7 1 Using Interaction Pages 7 1 Accessing Displays 7 1 Using Interaction Page 9 Display with a Workstation 7 1 Startup 7 1 Backup Option 7 1 Digital Input Filter Time Field 7 2 Serial Ports Field 7 2 Lockout and Log Options Field 7 2 Using Interaction Page 9 Display with an Operator Station 7 2 Startup 7 4 Backup Option Fie...

Page 5: ...Contents v CHAPTER 8 8 1 Alarms and Diagnostics 8 1 Annunciation of Alarms 8 1 Front Panel Numeric LEDs 8 1 ...

Page 6: ...neering 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...

Page 7: ...s 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...

Page 8: ...n 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 conne...

Page 9: ...ing 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 ...

Page 10: ...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 Mode Select DIP Switch Settings The mode switches located at the top of the front panel are used during DPU manufacturing and testi...

Page 11: ... 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 refer to next section Two LED displays refer to Two LED Displays There are no internal switches or jumpers ...

Page 12: ...t 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 ...

Page 13: ... 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 Green DPU online and active Offline Red DPU offline Inactive Yellow DPU online but inactive backup pair Battery Red nickel cadmium or lithium battery bad Yellow nickel cadmium battery ...

Page 14: ...xecuting DO Fast Digital Output Scanning green all points good red all points bad yellow some points good and some points bad off no points executing Per IO Periodic Input Output scanning Analog Inputs Control Blocks Data Blocks green all points good red all points bad yellow some points good and some points bad off no points executing Prog IO ExCEL Input Output Scanning green all points good red ...

Page 15: ...81388 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...

Page 16: ...he 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 b...

Page 17: ...uts 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 I...

Page 18: ... 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 t...

Page 19: ... 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...

Page 20: ... 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 The...

Page 21: ...y DPU a secondary DPU will never auto matically 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 se...

Page 22: ...condary 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 0...

Page 23: ...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 synchroniz...

Page 24: ...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 c...

Page 25: ... Locked mode 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 keylocks to the Offline position fully counter clockwise 2 Set ...

Page 26: ...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 rapidl...

Page 27: ...erform 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 pu...

Page 28: ...lace 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...

Page 29: ...ode 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 ...

Page 30: ...e 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 ex...

Page 31: ...ield In the Lock position you may disallow certain data DPU Bus operations from MIS HOST REloads or Screen Edits DPU Configuration Page Revision Date 14 OC 96 Level Time 09 32 12 MODE Run Active DHW 5 0 Model 530 Configuration Backup N CP 5 0 Stat Page IOM 5 0 DIGITAL FILTER TIME 10 MSEC SERIAL I O PORTS Port Baud Link Type Bits Char Stop Parity XON OFF RTS CTS No Rate 0 255 5 6 7 8 1 2 O E N IN O...

Page 32: ...OM 5 0 DIO Inventory I Input O Output A Alarm Only 1 9 17 25 2 10 18 26 Digital 3 11 19 27 Filter Time 4 12 20 28 10 msec 5 13 21 29 6 14 22 30 7 15 23 31 8 16 24 AI Inventory Address Alarm Channels Linearization by 16 Only 1 15 QUAD1 1 15 AI PAGE 14 14 QUAD2 16 30 15 15 QUAD3 33 47 DATA PT 14 14 QUAD4 48 62 15 15 Redundant I O Address Ranges R Redundant C Common 0 16 32 48 64 80 96 112 128 144 16...

Page 33: ... 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 ...

Page 34: ...he 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 Addres...

Page 35: ...5 246 247 248 249 250 251 252 253 254 255 Last Bad Module EVENT QUEUE POINTERS PUT 8489F4 20 08 820230 00 16 820230 00 24 820230 00 01 820230 00 09 820230 00 17 820230 00 25 820230 00 02 820230 00 10 820230 00 18 820230 00 26 820230 00 03 820230 00 11 820230 00 19 820230 00 27 820230 00 04 820230 00 12 820230 00 20 820230 00 28 820230 00 05 820230 00 13 820230 00 21 820230 00 29 820230 00 06 82023...

Page 36: ...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 Poin...

Page 37: ... READ THESE ITEMS 34 ABORTS TRANSMITTED 0 READ SINGLE ITEM STS 39 CTS LOST 0 WRITE THESE ITEMS IEEE 0 DCD LOST 90 READ THESE ITEMS QUALITY 0 CTS NOT ACTIVE 0 OLD SCAN TABLE MESSAGES 0 DCD ACTIVE AT TX TIME 2 NEW SCAN TABLE MESSAGES 40 MESSAGE RETRIES 160 UNEXPLAINED ERRORS 0 HEX MEMORY DUMP 000000 TOTAL DHW DIAGNOSTIC ALARMS 0 CW OPTICAL CABLE CHANGES 0 D7 01 F4 IF F8 FF 2E 94 CCW OPTICAL CABLE CH...

Page 38: ...h field appearing on the left side of the display The following table describes the right column statistics appearing in Interaction Page 12 COMMAND RESPONSE REJECTs 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 d...

Page 39: ...es 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 Ta...

Page 40: ...F F F F F F F F F F F F F TBll 0 TB12 F F F F F F F F F F F F F F F F TB12 0 TB13 F F F F F F F F F F F F F F F F TB13 0 TB14 F F F F F F F F F F F F F F F F TB14 0 TB15 F F F F F F F F F F F F F F F F TB15 0 TB16 F F F F F F F F F F F F F F F F TBI6 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TB17 F F F F F F F F F F F F F F F F F TBI7 0 TB18 F F F F F F F F F F F F F F F F F TB18 0 TB19 F F F F F F...

Page 41: ... 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 followi...

Page 42: ...received and the CP reported no other fatal alarm condition FD The DPU Bus Card waited for a response from the CP which was never received because the CP determined that its program code had been corrupted checksum error FE The DPU Bus Card waited for a response from the CP which was never received because the CP re executed its startup code unexpectedly jump or return to address 0 ...

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