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HA028225 Iss 3 - Temperature Control and Measurement from

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1. PC PC ALIN Hub Visual ArcNet SCADA Project studio supervisor 8 Terminator ALin ALin ALin ALin Process supervisor aaa ALin oo VOA ELS Unused ports need terminators CLLETI VOB O LL x NEM comms 0 PSU and relays comms Isolator Profibus E Isolator Ene VO sub system 2 VO sub system FIA282 Configuration E Configuration Terminal Terminal sub system 1 O sub system z 2 8 Terminator a ALIN connection Process Process PC PC SCADA Project studio Process supervisor Ethernet ELIN Hub EIA232 L Y Profibus E PSU and relays comme 5 solator sub system 2 sub system A EIA
2. 9 7 9 3 GOSH 9 8 IN DEX IN DEX 1 Section i HA028225 Pagei 8 Issue 3 Jly 04 PROCESSS SUPERVISOR HANDBOOK GLOSSARY OF TERMS Items in italics in the descriptions below also appear as glossary items in their own right 2500 ALIN ALIN bridge Application ARCNET Baud Brown out Cold start Cold Start time Configuration Control strategy CIDR COSHH CSP CSS DRAM Duplex EDB EEPROM ELIN EMC Eurotherm Project Studio e Suite FB FBD Function block GSD file Hot start Hot amp Cold start sub system for use with Process Supervisor units Local Instrument Network LIN protocol on ARCNET LIN to ALIN network link A LIN database and associated SFCs A single non branching masterless network running at 2 5MBaud allowing peer to peer communications and file transfer up to 100 metres Used to describe transmission speeds over communications links 9600 baud approxi mately 1000 ASCII characters per second A brown out is a transient power variation or partial power failure severe enough to prevent continuation of the process until the process supervisor has been re initialised A Cold start is where the instrument starts with the last loaded database loaded using either default parameters or parameters held in the cold start parameter file See also Hot Start Th
3. 2 when no automatic re start is required 3 when the start up preconditions for a redundant system are to be modified 4 when a new version of software has been loaded 5 when there have been modifications in the instrument hardware 6 inorder to clear redundancy start up data from memory Y unit secondary unsynch N Hot start N requested Y Hot cold star N requested Y Run hot Run hot start routine start routine fig 4 2 1b fig 4 2 1b iff N Test Was as Cold start start hot start N hot start requested successful successful Y Y Y Try to get DBF file that matches RUN file in Flash Was cold start n successful Y Create empty database Run data base Figure 4 2 1a Simplified start up flow diagram HAO28225 Chapter 4 Issue 2 Nov 03 Page 4 3 PROCESS SUPERVISOR HANDBOOK 4 2 START UP MODES Cont Entry from Hot or Hot Cold start routine Hot start called E see figure 4 2 1 Try to get DBF file that matches RUN file from FLASH Attempt successful Extract last known status from memory Set Brownout alarm in root block Return success Return Fail Figure 4 2 1b Hot tepid start flowchart Chapter 4 Page 4 4 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 4 3 STARTING A SINGLE NON REDUNDANT PROCESSOR 4 3 1 Start up sequence Figure 4 3 1 shows the locations of the various LEDs Proc
4. 5 11 5 13 7 introduction 2 1 2 Circuit board 41 11421 8 6 8 7 MU 8 8 Clock back up times n 2 15 DEus e A M eed 5 20 Coherence dette e eda 7 6 Duplex Gold start hetero E 3 9 IRE 3 8 4 8 6 5 Parameter file 0 4 2 oe du fara eee baec toa 4 1 Comms Dynamic tuning iee snaa Aas 7 5 LEDS iue enaa ait ec es ior 4 9 Parameters dumb terminal 2 17 HA028225 Index Issue 3 Jly 04 Pagel PROCESS SUPERVISOR HAN DBOOK E tig hie 5 14 y o Editing a database 5 7 Calibration ee 5 14 ELIN connectors 2 11 Connectors i oA 2 12 ELIN setup 5 16 Connectors SysA 2 11 Error azul 6 7 Codes introduction siete eei t mere 1 3 Asynchronous 6 18 LEDs i oA 2 3 5 4 9 Config files 91 6 16 ICM Control config 87xx 6 15 Action ON fall ert ems 6 6 Database 83xx 6 14 Diagnostics
5. 2 15 LED Alarms uini acne 3 4 F Battery 3 3 Communications 3 5 4 9 Fan replacement ER EAE eee eit 8 3 3 8 4 8 4 9 4 12 6 5 Field ea rac ie te v iras 7 7 1 anus 3 5 4 9 FILE 5 15 Ue Boer tet m Se ea OE Chee gat cea 3 5 4 9 Filename 5 14 Indication at start up 4 5 6 10 Filter replacement 8 2 PowertAB a dia 3 3 4 9 Firmware 0 8 5 PIMAN see dus re t e 3 6 40625 Flash card 8 5 RIRIA MEA 2 4 Bane eaves 5 15 5 20 Standby 3 6 4 8 6 5 ZR Start up fault indicator 4 9 Annunciation introduction 1 2 System ee ER es 3 5 4 9 Connection 44 2 9 JGSE eese tete ende nic 8 13 Error displays id cene etes 6 2 Watchdog wdog 3 8 4 9 Processor module 3 1 4 5 6 2 LIN Local Instrument Network 5 13 FUN ce 2222 24 6 12 E E Ohare acetate T 5 5 Function blocks 5 6 ORAN
6. RxB 5 wire 7 9 m daii RxA 3 wire Screen White Orange View on rear of connectors Figure 2 5 14 9508 5 2RJA5 connection details Chapter 2 HA028255 Page 2 12 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont ELIN HUBS The use of standard off the shelf Ethernet hubs is recommended using Straight through cables figure 2 5 1 For further details the LIN ALIN ELIN installation and user guide HA082429U005 should be referred to ALIN HUBS ACTIVE Figure 2 5 1 shows a simple ALIN hub layout and figure 2 5 1f a daisy chain layout The hub layout is preferred cases where the integrity of the ALIN network is considered to be susceptible to lengths of daisy chain becoming inoperative due to cable breakage or individual hardware faults ALIN Network N Process supervisor PC ALin ALin Unused ports Eurotherm I O B need terminators _ 4 Terminator Project Studio o Remote o Terminator t Figure 2 5 1e ALIN Hub layout ALIN Hub Arcnet ALin network 5 Terminator PC Terminator Eurot
7. 2 5 MOd6eS sett dn dit Mees 4 1 Monitor 4 4 0 440 44008 8 7 8 20 States x eom Mut Hoo eT ge rene il SEN a 6 4 M MO AW M CM E ae ee 4 10 6 11 Retresh r te a EE 5 8 System S mon 4 44 4 4440 4 6 11 al 5 19 N Relay Specification ssena inen en ess 9 3 5 1 5 13 5 21 ERR e nett 2 16 Set p page ssim e redis 5 13 Remote device eene ene 5 15 Non coherent data transmission 7 7 Repeat times oerte peptide 7 5 Replacement procedure Battery internal 8 4 Options switch SW 2 7 Cooling TANS 385 8 3 Order codes 9 6 9 8 sect ed eed chee eee she kta 8 2 Pre eA C ere Restart switch 0 00238 8 P RJ45 Connectors 2 14 Package contents 2 3 5 Baa mE 6 13 RE 6 11 8 16 8 20 Database 5 8 Safety requirements 2 24042 2 2 220 SAVE 5 1 5 14 5 21 Se dit SDX IDLO ieee 12 Maltese iaa ete 5 9 SDX RSRC 6 12 iiu cett debes 2 17 5 3 5 17 nM QM MP ME RENE IN sore na 5 7 Secondary Polling Cycle Modbus 5 19 oe tases an adage es Pollution
8. Hl r2 wdog batt 24V A B left processor right processor Figure 2 3 1 Connect module front panel layout Chapter 2 Page 2 4 HAO28255 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 3 2 Removal of modules It is recommended that power be removed and all wiring be disconnected from the connection module before it is removed from the backplane Although Processor Modules are designed to be removed replaced with power applied the life of the connector will be maximised if they are removed with power off Note Figure 2 3 2 shows aconnection module The procedure is identical for processor modules To remove a module 1 Remove wiring by disconnecting connectors 2 Unscrew both retaining screws anticlockwise to jack the unit out of its connector 3 Lift the unit off its retaining catch 2 Undo jacking screws 0 6 1 Remove wiring 2 3 3 Fitting of modules Figure 2 3 2 Module removal 1 Lift the module onto its retaining catch and gently push the module towards the backplane to mate the connector Caution Do not force the unit onto its connector or damage will occur 2 Re engage and tighten both retaining screws a few turns each at a time to a maximum torque of 2 5 Nm 2 4 BACKPLANE SWITCHES 2 4 1 Location HAO28225 Chapter 2 Issue 2 Nov 03 Page 2 5 PROCESS SUPERVISOR HANDBOOK The backplane switches for setting communications addresses a
9. Name Range TLV Toxicological data Nickel hydroxide 10 Not established Highly toxic if ingested Nickel metal 20 26 Not established Misch metal alloy 10 11 Not established Potassium hydroxide 8 Not established Highly toxic Highly corrosive Boiling point Not applicable Specific gravity Not applicable Vapour pressure Not applicable Solubility in water Not applicable Odour Not applicable Colours Not applicable FIRE AND EXPLOSION DATA Flash point deg C Method used Not applicable SEE Eee LEL UEL Any Not applicable Not applicable Extinguishing media Special fire fighting procedures Not applicable Batteries might explode due to excessive presure build Unusual fire and explosion up which might not be self venting Toxic fumes might hazards be generated HEALTH HAZARD DATA Threshold limit value Not applicable LD 50 Oral Not applicable LD 50 Dermal Not applicable Skin and eye irritation Should cells leak the leak material will be a caustic solution Avoid contact Over exposure effects Not applicable Chemical nature See above There are no risks in normal use FIRST AID PROCEDURES If leakage occurs wash the affected area withplenty of water and cover with dry gauze Eyes and skin If eyes are affected wash with plenty of water Seek medical assistance Ingestion If ingestion of leak material occurs DO NOT
10. 2 2 PERSONNEL ed steed itd oa Sach 2 2 HAZARDOUS VOLTAGES 2 20 00 0 2 2 CONDUCTIVE 2 2 VENT LATION 2 2 PRECAUTIONS AGAINST ELECTROSTATIC DISCHARGE 2 2 2 1 3 Keeping the product safe 2 2 MISUSE OF EQUIPMENT 2 2 SERVICE AND REPAIRS 2 2 2 2 UNPACKING buch coving Pere lee deel Teun tess 2 2 2 2 1 Handling precautions 2 3 2 2 2 Package 2 3 PRODUCT LABELING 2 6 c eer th rt eet Snake aoe 2 3 2 3 MECHANICAL LAYOUT AND INSTALLATION sse 2 3 2 3 1 Layout drawings 1 2 402021 04 104 4 1 00000 2 4 2 32 Removal oF modules dt ee tr etie 2 5 2 3 3 Fitting Of modules eerte e teens 2 5 2 4 BACKPLANE SWITCHES e BE Pte Ee P EES 2 5 2 4 1 se ae bee 2 5 2 4 2 Swilch functlons besa in iti de rte dero tendere 2 6 SW1 LIN ADDRESS SETTING SWITCH 2 6 SW22 OPTIONS SWITCH cs it recitat tete trt tbe eet uet 2 7 WDR WATCHDOG RETRY pce EE ER 2 7 MODBUS ENABLE 2 7 SRD REDUNDAN
11. SWe2 OPTIONS Example of how to set address pair 7A 7B Bit 0 automatically set to 0 thus 7A for left processor and to 1 7B for right processor Addresses 00 FE and FF are reserved and MUST NOT be used Figure 2 4 1 Location of backplane switches Chapter 2 HA028255 Page 2 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 4 2 BACKPLANE SWITCH FUNCTIONS Cont Sw2 OPTIONS SWITCH Figure 2 4 2b below shows the Options switch SW2 located on the backplane as shown in figure 2 4 1 above Sw2 Options Off 0 Not used 5 Not used SRD 6 cm Redundancy disable MDB 5 Ca Modbus enable 4 Not used Not used WDR 1 CHI Not used Watchdog retry enable Figure 2 4 2b Option switch layout WDR WATCHDOG RETRY Setting this switch segment on slide to the left causes the processor to try to start again after any watchdog failure Setting the segment off slide to the right disables the re try and the processor will need manual restart after watchdog failure MDB MODBUS ENABLE Setting this switch segment on slide to the left enables Modbus communications if fitted Setting the segment off slide to the right disables Modbus Communications see note 2 below SRD REDUN DANCY DISABLE Setting this switch segment off slide to the right selects redundant mode with t
12. Feo ERR cue EE OR ER REIR aes 4 9 POWER A B itii Pte iO e tais eM 4 9 2 Seana 4 9 PRIMARY eai ebd 4 9 COMMS LEDS ig ate e t eed o ade dan dies 4 9 SYSTEM AND 5 i iori rit eerte i etes een 4 9 EXP EXP2 LEDS 5 deo e test ree su sae eevee 4 9 DUPLEX LED eyes etr etn c et te e ETR 4 10 4 6 START UP WITH CONFIG TERMINAL eee 4 10 zo M Wem 4 10 4 7 START UP WITH SERVER STALL i iiie ere ctt rt e di aia iia 4 11 4 8 REDUNDANT MODE WORKING 4 11 4 8 1 Redundancy decisions e 4 11 4 82 Profib s Exatmples eet ce n 4 12 Cont Section i 028225 4 Issue 04 PROCESSS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page CHAPTER 5 CONFIGURATION 5 1 5 1 TOOLS THE CONFIGURATOR AND LINTOOLS 5 1 5 2 CONFIGURABIE ITEMS tp bb de e HO 5 1 5 2 1 Configuration Access 000 0 5 2 5 3 PREPARING TO RUN THE CONFIGURATOR 99 5 2 5 3 1 Connecting to atP C uice eee an BEER eee ha NES 5 2 5 3 2 Setting the control efficiency
13. e eed ie 5 17 5 6 L MODE es e EE en 5 17 D622 SETUP sade haath oo eth E 5 17 5 6 9 Tables ose aa At ee Eee aa 5 18 TABLES LIST ed RP a eden 5 18 TABLE MENUJS eR RERO gts 5 19 5 64 Utilities reete EURO E RR ERE OR RENS 5 21 Cont 028225 Section i Issue 3 04 Page i 5 PROCESS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page CHAPTER 6 ERROR CONDITIONS amp 6 1 6 1 ERROR INDICATION TYPES ene enne rne 6 1 6 2 PROCESSOR MODULE FRONT PANEL ERROR 6 2 6 2 1 AEDs eed ode cy 6 2 6 2 2 Processor failure modes 2 6 4 6 2 9 Power failure sere eme Cue HT dn 6 5 PRIMARY PROCESSOR 22 6 5 SECONDARY PROCESSOR MODULE 6 5 6 2 4 Watchdog failure 22 2 6 5 6 2 5 ICM Inter CPU Messaging for redundancy failure 6 5 ACTION IN THE EVENT OF ICM FAILURE 00002 6 6 6 26 LIN Tail fe oer ET le es 6 6 EFFECT OF LIN FAILURE ON REDUNDANCY MODE CONTROL 6 6 6 27 oe en RU ee n rne 6 7 6 2 8 O Gomm
14. 000 Found board 1 at CA000H Select terminal type 1 ANSI CRT gt gt gt Typing 1 calls the Profibus test page and typing D refreshes the page with current data as shown below which shows as an example node 4 as being the only node on the network After positioning the cursor next to node 4 the space bar can be operated to call the master data page or the carriage return key can be used to call the slave data page also illustrated below Section 8 028225 Page 8 10 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 5 DIAGNOSTICS MENU Cont PROFIBUS TEST Cont CYCLC ACYCLIC Maintaining Network 1 Output 4500 4000 cyclic ramp Input from node 2 non existent A 3 non existent gt 4 4000 100 Y 5 non existent 6 non existent 7 non existent 8 non existent 9 non existent 10 non existent 11 non existent T 12 non existent 13 non existent 14 non existent 15 non existent not activated 16 non existent zi fault 17 non existent select page copy node setup X remove node arrow select node P paste node setu sp view master return view node A paste to all D download amp activate MASTER DATA SCREEN Board 1 at 000 not activated Date 01 03 2001 Type model 55 67 Device no 10704090 O S code Serial no 00000731 Firmware PB COMBIC104 PB DPRAM size 8 kBytes V01 05
15. 7 5 Cursor control key combinations 5 4 Backplane switches 2 5 Daisy chain CONNECUOM 2 14 External 2004 2 15 Data 8 4 4 444 00 1 4 2 17 5 3 Fus Valug siis 2 15 3 3 Data coherence 7 6 eds tete dicic 2 15 Database Bleplacermenkafs 8 4 Lec T 6 5 6 7 Stats MEDS ssc tec ee outa 3 3 Name and address 4 1 5 13 Baud 2 17 5 3 5 17 Startup neci 7 5 BIOS LEDS sssini 6 10 Transfer between modules 8 5 5 11 DC supply Eie ca Ate 5 6 5 7 FUSING 42 40 4 008 0009 04 80 4 0 2 15 3 3 Ser Vel Sv e d 6 12 Wiring eee 2 15 structure introduction es 1 3 D cimal point seat e e pn eis 5 9 SUDDEN Dun tae E 1 3 Default gateway 0 4400 5 3 5 16 Updates eee lade 7 7 DELETE 5 1 5 12 5 21 3 6 Desynchronisation 6 5 6 12 DIAG 2 80 6 12 Cables and accessories 9 7 Diagnostics Cached blocks
16. e tdt 7 2 LOAD P M 7 2 BOND TASK SGANI z 1 eto ire estet eat ertet rete re cert 7 2 IDLE TASK 55 DERE STE re tds entes adit detis 7 2 742 USER TASKS 3 c tet Rt EO DE 7 3 7211 Terminology eS 7 3 USER TASK iii Pe ner 7 3 SERVER i Eae cad eod E 7 3 7 2 2 User lask servers niet Fac cere Fete tee eee esee teet ae e tanner oe eme Raetia 7 3 SERVER INTERACTIONS scie vo ree e 7 3 USER TASK SERVER OPERATION 7 4 7 3 USER TASK TUNING rer beri ceret bt Hte 7 5 7 3 1 Repeat times amp execution times 7 5 7 3 2 Automatic dynamic tuning 7 5 7 3 3 Manual t ning e kai 7 5 74 etie redit ere erdt hse 7 6 7 4 1 Data flow between tasks 22 2 2 7 6 CONNECTIONS INTO TASKS FROM OTHER TASKS IN THE SAME INSTRUMENT NODE 7 6 CONNECTIONS INTO THIS TASK FROM OTHER TASKS IN ANOTHER INSTRUMENT 7 6 CONNECTIONS OUT OF THIS TASK TO ANOTHER NODE 7 7 Cont 028225 Section i Issue 3 04 Page i 7 PROCESS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page CHAPTER 8
17. E ZI a 1 i 1 ME mE EC View rear of connectors Ax 2442420 Cross over cable 22 4 Figure 2 5 1 connection details 028225 Chapter 2 Issue 2 Nov 03 2 11 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont ALIN CONNECTORS The Connect module contains two pairs of ALIN RJ45 type connectors called i oA The left hand pair is for the left hand processor the right hand pair for the right hand processor The two sockets making up each pair are connected in parallel to allow easy daisy chaining Connection with an ALIN hub or a PCI ArcNet card also fitted with 8 way RJ45 connectors can be made using an RJ45 to RJ45 cable assembly available from the manufacturer under part number S9508 5 2RJ45 This cable has all eight connections made at both ends thus making it suitable for all applications not just ALIN which uses only a single twisted pair Fig 2 5 1d is a schematic showing the connections Notes The Rx and Tx legends apply to Modbus master connectors Slave connections have Tx and Rx reversed as shown in figure 2 5 1b above 2 Wire colours shown may not be correct for your cableform EATEEEE SHROUD SCREEN aa TxB 5 wire 1 J White Orange 1 EIA485B 3 wire 4 d TxA 5 wire 2 EIA485A 3 wire Orange ov White green P 3 Blue ALIN phase A 4 Blue white ALIN phase B
18. ENG A A A A Bulkhead fixing backplane connect module BU 19 rack mounting backplane connect module 19 No base no connect module Battery Language Elin Profibus Modbus master Modbus Slave EXPMM Elin Modbus master Modbus Slave EXXMM Alin Profibus Modbus master Modbus Slave XAPMM Alin Modbus master Modbus Slave XAXMM Modbus master Modbus Slave XXXMM Elin Profibus Modbus master Modbus Slave EXPMM Elin Modbus master Modbus Slave EXXMM Alin Profibus Modbus master Modbus Slave XAPMM Alin Modbus master Modbus Slave XAXMM Modbus master Modbus Slave XXXMM No 2nd processor Blanking plate fitted BLK No 2nd processor No blanking plate Backup battery fitted BAT No backup battery fitted English language ENG Base Blanking type plate ENG A Bulkhead fixing backplane connect module BU 19 rack mounting backplane connect module 19 Language Language Tazo ENG Blanking plate fitted at 2nd processor position BLK No blanking plate required English language ENG English language ENG Figure 9 2 1 Instrument ordering guide Section 9 HA028255 Page 9 6 Issue 04 PROCESS SUPERVISOR HANDBOOK 9 2 2 Spares and accessories Internal te mem mte ee AH261438 Cable harness for batte
19. SECONDARY PROCESSOR MODULE A power failure in the secondary unit of a redundant pair will cause the primary unit to enter the Primary Unsynch state 6 2 4 Watchdog failure In the event of a watchdog failure of a processor module the green watchdog LED is illuminated red and the affected processor module enters a Watchdog fail state In this state the indications given by the standby primary and comms LEDs are unreliable and should be ignored Operation of the RESTART button resets the watchdog and restarts the CPU if this is possible On watchdog failure of a processor module in redundant mode the surviving processor module adopts or maintains the PRIMARY UNSYNCH state And as in the case of power failures the survivor runs the database only if it was synchronised before takeover halting it otherwise 6 2 5 ICM Inter CPU Messaging for redundancy failure Note An ICM failure is not associated with any single processor module and so is not classed as either primary or secondary in figure 6 2 2 An ICM failure is indicated by the standby and duplex LEDs when the primary and secondary processors can no longer communicate with each other across the internal high speed link making database synchronisation impossible to maintain Figure 6 2 2 shows that an ICM fail causes desynchronisation of the processor modules but no primary secondary changeovers STANDBY LED Off Duplex LED Off No communications link
20. Invensys EUROTHERM Invensys EUROTHERM Declaration of Conformity Manufacturer s name Eurotherm Limited Manufacturer s address Faraday Close Worthing West Sussex BN13 3PL United Kingdom Product type Process Supervisor Models T940X Processor module Status level A1 or higher T320 Connection Module Status level T12 or higher T310 Backplane Status level T11 or higher Safety specification BS EN61010 1 2001 02 EMC emissions specification BS EN61326 2002 02 EMC immunity specification BS EN61326 2002 02 Eurotherm Limited hereby declares that the above products conform to the safety and EMC specifications listed Eurotherm Limited further declares that the above products comply with the EMC Directive 89 336 EEC amended by 93 68 EEC and also with the Low Voltage Directive 73 23 EEC Signed x aus Dated AY 2004 Signed for and on behalf of Eurotherm Limited William Davis General Manager 1A249986U610 Issue 2 Aug 04 C 2004 Eurotherm Limited All rights are strictly reserved No part of this document may be reproduced modified or transmitted in any form by any means nor may it be stored in a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates without the prior written permission of Eurotherm limited Eurotherm Limited pursues a policy of continuous development and product
21. or Return Section 8 028225 Page 8 12 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 5 DIAGNOSTICS MENU Cont LED TEST Selecting 6 from the Diagnostic menu allows an LED test sequence to be initiated as described below The test is started by selecting 1 from the LED sub menu The test sequence is as follows Duplex LED switched green red off battery int LED switched green Off at step 16 battery ext LED switched green Off at step 17 System A LED switched green red off System B LED switched green red off i o A LED switched green red off i o B LED switched green red off Standby LED switched yellow Off at step 18 Primary LED switched green Off at step 19 10 Exp Tx LED switched yellow Off at step 20 Type 2 lt CR gt 11 Exp1 Rx LED switched yellow Off at step 21 to stop test after step 25 12 Exp2 Tx LED switched yellow Off at step 22 13 Exp2 Rx LED switched yellow Off at step 23 14 rl1 LED switched yellow Off at step 24 15 112 LED switched yellow Off at step 25 16 battery int LED switched off 17 battery ext LED switched off 18 Standby LED switched off 19 Primary LED switched off 20 Expl Tx LED switched off 2 Expl Rx LED switched off 22 Exp2 Tx LED switched off 23 Expl Tx LED switched off 24 rl1 LED switched off 25 112 LED switched off PWN If not stopped by typing 2 lt CR gt
22. 8 1 8 1 PREVENTIVE MAINTENANCE 5 2 2 8 1 8 2 REPLACEMENT PROCEDURES 2 8 2 8 2 1 1 dear prece qi ede qal 8 2 8 2 2 Chassis Fan replacement 8 3 8 2 3 Capacitor board capacitor board fan 8 4 8 2 4 Battery board replacement 8 4 PROCEDURE sch Aina ee 8 4 8 2 5 Flash card 8 5 8 2 6 Firmware upgrade reet eene tte titer Detroit 8 5 8 3 PHYSICAL ARRANGEMENT INSIDE PROCESSOR MODULE 8 6 8 4 THE MONITOR turbet estes 8 7 8 4 1 Top level main menu access 2 Re 8 7 8 4 2 Quite antes 8 7 8 4 3 Help iii tidem re a RE RR UG bte dhe ees RE DS 8 7 8 4 4 Display saved system features 8 8 8 4 5 Diagnostics meni nsira dp elie et EA 8 8 AUTOMATIC TEST 5 8 9 PSE COMM TEST 8 9 NET MEIN ope ede 8 10 PROFIBUS TEST cs 8 10 MASTER DATA SCREEN 2 8 11 SLAVE SCREEN reete 8 12 8 4 6 Manual Setups tech ene eth eem edu eg cde gg 8
23. Chapter 6 Page 6 18 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 7 TASK ORGANISATION amp TUNING All in built and user programmed instructions are performed serially i e one at a time The first section of this chapter describes these various software functions tasks and their scheduling within the instrument The next section de scribes user tasks and their associated loops and servers User task software structure and server operation is also out lined Finally user task tuning by varying minimum repeat rates is described 7 1 TASK SCHEDULING 7 1 1 Tasks A task is a unit of software that is responsible for carrying out particular duties at certain times usually while the data base is running There are 24 recognisable tasks in the Process Supervisor Most tasks are fixed and cannot be varied by the user Others the user tasks are programmable and are described in section 7 2 below 7 1 2 Priorities Each task has a priority based on its importance to efficient and safe operation Priorities are numbered from 1 highest to 24 lowest A task once started will run to completion unless it is interrupted at any time by a task of higher prior ity In this case the lower priority task suspends activities until the higher priority task has finished at which point it resumes running These interruptions are hierarchical several tasks may be held in suspension by higher priority tasks at any one tim
24. Primary synch Primary synching ILEDs Power Watchdog Primary flash LEDs Power Watchdog Primary Comms mmm Comms ICM failure ICM failure 1 comms failure Any 2 failure Any 2 failure 1 LIN failure Database halt Database halt Primary unsynch LEDs Power Watchdog Primary Comms Any 1 failure Any 1 mdi fe 1 power down DON Secondary synch 1 watchdog failure Secondary synching LEDs Power Watchdog Standby flash LEDs Power Watchdog Standby Comms V ICM failure ICM failure 2 LIN failure 312 LIN failure 2 comms failure 2 comms failure Database halt Database halt unsynch LEDs Power Watchdog Figure 6 2 2 Processor unit failure modes Chapter 6 028225 Page 6 4 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 2 3 Power failure In the event of a power failure all the LEDs associated with the affected processor are extinguished and the processor adopts the OFF state PRIMARY PROCESSOR MODULE A power failure in the primary unit of a redundant pair will cause the secondary unit to adopt the Primary Unsynch state If the secondary was not synchronised at the time the database halts The new primary s PRIMARY LED flashes to show that the database is not running If the secondary was synchronised at the time of takeover the database continues to run in the new primary PRI MARY LED on continuously
25. 07 9 08 9 09 9E0A 9 9 0 9EOD 9EOE 9EOF 9E10 Lock has entered an inconsistent state and cannot be granted Lock was not granted in the required mode Timeout attempting to acquire Unable to convert mode of lock Already hold a read lock Already hold a writer lock Do not hold a read lock Do not hold a writer lock Write lock detected during read unlock Reader lock detected during write unlock Unable to grant read to write conversion as a con version of this form is already in progress Unable to represent user in lock control structures Ick_Unlock invoked but not enabled Nesting requested but lock not a mutex Overflow of nested mutex Unable to convert a nested mutex 00 Error releasing signal waiters MAL Table 6 6 2u MAL error codes AOxx A101 Cyclic comms enabled on node s A102 A103 A104 A105 A106 A107 A108 1 10 10 A10D 10 10 A110 No memory left Bad info given Data is referenced No data group installed Pending message Fault external to AMC Not supported Conflict Task not running Bug Manual cyclic only pmc reject Cannot add cyclic request Slave rejected cyclics No pmc callback Table 6 6 2v AMC error codes A1xx A401 A402 A403 A404 A405 A406 A407 A408 A409 A40A A40B Out of Bad resource s Bad info supplied Pending message Problem external to MMC Not supported Timeout Frame parity error Currupt message Link
26. For Profibus if the Error Weight for the primary processor is higher than that of the secondary processor the units will desynchronise If both units have an Error Weight of 1 the units will change over to try to achieve a better result For LIN systems if the Error Weight for the primary processor is higher than that of the secondary processor the units will desynchronise If the Error Weight for the primary processor is lower than that of the secondary processor the units will change over The decision to remain synchronised to desynchronise or to change over is always made by the current primary processor and then only whilst the two units are synchronised An attempt to synchronise will be allowed to complete and only after completion will the decision be made The decision is also deferred if the Error Weight is unstable This prevents spurious desynchronise or changeover decisions being made as faults are introduced to or removed from the network 1 OB LED Description Steady Communications running successfully green The unit is running Profibus and successfully Flashing 224 z green communicating with at least one slave but i oB only other slaves not responding This fault cannot appear on a Redundant Secondary as the necessary information is not available to it Flashing The unit is running but it cannot communicate Faulty red e g because of a cable break network Faulty
27. Master Slave Typing 5 displays the message Chl master gt Y y N n Typing Y or y sets EXPI to Master status Typing N or n sets it to Slave status Typing 6 is similar but for EXP2 port Start loop test 3W 5W Typing 7 or 8 starts the loop test for 3 wire or 5 wire systems respectively once the number of repeats has been entered Note that the number of repeats received should be the same as the number of repeats requested before the start of the test If this is not the case there is a problem with the communications link Continued HA028225 Section 8 Issue 2 Nov 03 Page 8 9 PROCESS SUPERVISOR HANDBOOK 8 4 5 DIAGNOSTICS MENU Cont PSE COMM TEST Cont Enter required number of repeats No of errors detected n Comm 1 Comm 2 No of errors detected 2 RX Comm 1 N4 No of repeats received 1 Bi ci Comm 2 N4 No of repeats received in Comm 2 ps DUTE L ICOntTENES Contents of buffers at end of test EX i668 buff 2 Contents The PSE Comms test menu is re displayed on the screen allowing the user to quit the test or to repeat it perhaps at a different Baud rate NET MENU Not used with this version of software PROFIBUS TEST Accessed by typing 4 this allows profibus communications to be tested starting with the following screen Profibus test Looking for boards in address range 000
28. Operation of this push switch causes the relevant processor to restart in the mode selected on the rotary mode switch immediately below it Used after a watchdog failure has occurred Chapter 3 028225 Page 3 8 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 3 6 4 Halt switch Operation of this switch for more than four seconds causes a watchdog failure to stop the processor In a redundant system Halt on the primary processor causes the secondary to take over This function is normally used only during commissioning or servicing 3 6 5 Start up mode This is selected at an eight position rotary switch with its positions labelled Hot Hot cold Cold and Test 180 switch actuator positions are wired identically such that position position 5 position 2 position 6 and so on A full discussion of start up modes is given in chapter 4 HOT A time out period can be configured by the user for hot start and this period varies from application to application The time out period is defined as that period after the database has stopped running within which the data base can be re started without noticeably degrading or endangering the control process If a restart is requested within this time and the database is still valid the processor will restart using the last known data base If the data is not valid the last loaded database file overlaid with tepid data stored at the end of each iteration is used I
29. Table 5 4 1 Cursorcontrol equivalent key combinations Some tables allow a value to be entered directly or via a called up menu For direct entry the first character s of the chosen option is are typed followed by Enter Alternatively the menu can be accessed with Enter or Tab as the first character after the field is selected IP SUBNETS The current IP address system is known as Classless Inter domain Routing CIDR The process supervisor predates this standard and divides the internet address space into a number of classes see table 5 4 1 below For this type of addressing the subnet masks on byte as opposed to bit boundaries Therefore a subnet mask for a class C address such as 255 255 252 0 is converted to 255 255 255 0 In order to avoid misinterpretation of the information in the NETWORK UNH always use valid pre CIDR subnet masks Address Example Default subnet mask 0 network 7 bits host 24 bits 90 1 2 3 255 0 0 0 10 network 14 bits host 16bits 128 0 1 2 255 255 0 0 110 network 21 bits host 8 bits 192 0 0 1 255 255 255 0 1110 multicast group ID 28 bits 224 0 0 1 None Table 5 4 1 Address space class definitions Section 5 028225 Page 5 4 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 4 2 The Initial menu The Initial menu figure 5 4 1 above lists two options Database and Gateway Database allows access to the Main menu for configuring a LIN database
30. This is described in section 5 5 Gateway allows access to the Gateway menu for setting up a Modbus configuration described in section 5 6 5 4 3 Quitting the terminal emulation program Exit from configuration mode must be done from the terminal by pressing lt Escape gt repeatedly until the main menu screen appears then again to clear the screen The processor is now out of configuration mode Note It is not possible to stop start download upload files via Network explorer E suite package for a processor in configuration mode Any attempt to do so results in error 8333 Configurator in use being reported Processor configuration mode must be quitted before these operations are attempted Caution Always quit the primary processor from configurator mode after use If this is not done an operator unaware that the Processor module is still in configurator mode might subsequently plug in a terminal and type lt En ter gt lt Enter gt hoping to see the version and power up shutdown messages The result could be totally un expected because the configurator would react according to where it was left e g if last used to start a data base it would execute the start sequence twice 5 5 DATABASE CONFIGURATION Figure 5 5 shows the Main menu MAIN MENU Select option gt MAKE Create block COPY Copy block DELETE Delete block INSPECT Inspect block NETWORK Network setup UTILITIES
31. Try to get DBF file that matches RUN file from FLASH N Return Fail Attempt successful Relevant error message Y Overlay Tepid data N Return Fail Root block is invalid root block valid Is the real time clock valid N Return Fail Real time clock not running N Return Fail Root block clock not running root block clock Y Extract last known status from memory Return Fail Cold start time was exceeded Set Brownout N alarm in root block Return success Figure 6 3 1b Processor unit warm start routine flowchart simplified 028225 Chapter 6 Issue 2 Nov Page 6 9 PROCESS SUPERVISOR HANDBOOK 6 4 POSTS POWER ON SELF TESTS Whenever a processor module is powered up it automatically performs a series of diagnostic tests The results can be displayed on a VDU terminal plugged into the EIA232 CONFIG port in the processor front panel as described in Chapter 5 of this manual Note It is recommended that the terminal screen be cleared lt Ctrl gt lt W gt prior to use If the screen has not been cleared the POST output may merge with the existing display and be unreadable At switch on the Basic I O system BIOS starts running and checks that the Central Processor Unit CPU is operat ing correctly This stage of power up is apparent by the intermittent lighting of what are called the BIOS LEDs shown in figure 6 4 below
32. before a service call is made Error messages A large number of highly specific error messages are transmitted mainly during start up by the processor modules which can be viewed if a VDU terminal is attached via the EIA232 CONFIG port on the front of the processor unit POSTs results of power on self tests POSTS can be used to pinpoint error conditions in the instrument Diagnostic blocks A range of function blocks can be included in the running strategy database to provide diagnostic informa tion on various topics including the redundancy mechanism the ICM inter processor communications the I O interface and others 028225 Chapter 6 Issue 2 Nov Page 6 1 PROCESS SUPERVISOR HANDBOOK 6 2 PROCESSOR MODULE FRONT PANEL ERROR DISPLAYS 6 2 1 LEDs Figure 6 2 1 shows the processor module front panel LEDs Table 6 2 1 specifies their functions Process Supervisor Processor POWER 24V O Q int ext battery EUROTHERM suite Om m ALARMS COMMS system O O A B ilo OO OO rx OO exp exp2 PRIMARY syne desync changeover ED RESTART wdeg halt C duplex CONFIG Figure 6 2 1 Processor module front panel Chapter 6 Page 6 2 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 2 1 LEDs C
33. see chapter 4 for details and about what faults might have occurred to cause a processor module to stop running the data base If the LED is flashing red green the module is in start up mode If the LED is illuminated continuously green the processor module is running normally as far as the software is con cerned and there are no detectable hardware errors If the LED is illuminated continuously red the processor module is in reset as a result of one or more of the follow ing errors having been detected 1 One of the cooling fans has failed during start up If a fan fails at any other time an alarm is set in the header block The processor circuits have overheated The processor clock is not running Halt switch has been operated A software fault has forced a Halt Qn e As shown in Chapter 2 figure 2 4 2b sliding segment 1 of SW2 to the left will cause the processor repeatedly to try to re start after a watchdog failure Sliding the segment to the right disables this re try facility and the processor has to be re started by the user 3 6 2 Duplex LED This LED is illuminated green if the inter processor communications are valid and successful data transfers are tak ing place between the two processor modules Applies only to redundant systems The LED flashes red green if the interprocessor communications have failed The LED is off if the system is not running in redundant mode 3 6 3 Restart switch
34. unit Remove the fan from the capacitor board by undoing the securing M3 nuts and bolts To replace the fan only continue at step 7 To replace the capacitor board only continue at step 8 7 8 9 Discard the old fan and fit the new one to the board using the fixings previously removed Continue at step 9 Fit the fan to the new capacitor board using the fixings previously removed Continue at step 9 Fit the capacitor board into the unit and secure it using the support plate and four screws previously removed 10 Re mate the capacitor board connector F and the fan connector E 11 Re assemble the instrument 8 2 4 Battery board replacement WARNING The battery being replaced is likely to be partially charged and must not be short circuited intentionally or inadvertently as to do so carries a risk of explosion with possible emission of dangerous and corrosive materi als Notes 1 Replacing the internal battery board causes the Real time clock to be lost 2 Although the battery on the replacement board is supplied partially charged it is recommended that in order to achieve its specified back up performance it must be left in its processor module with power applied for approximately 48 hours If power is removed before this period data retention time will be reduced accordingly PROCEDURE 1 Prepare the processor module by carrying out section 8 2 1 steps 1 to 4 2 Lay the module on one side
35. 1 PROCESS SUPERVISOR HANDBOOK 7 1 3 TASK FUNCTIONS Cont LLC TASK This task runs every 100 msec approx and monitors the low level status of the LIN link The task applies timeouts to transmitted messages and reprograms the LIN hardware if error conditions are detected LOAD TASK This event driven task runs only when a remote request to load a database is received BGND TASK Scan This task collates alarm information and carries out sum checking of the database The task runs continuously as long as the database is running IDLE TASK This purpose of this task is to provide a task environment in which the CPU can run when there are no other tasks running The task is not run whilst the database is running Tick Provides system clock Every 5 msec Note 1 Rx ICM Processes messages received over the ICM Event driven Rx LIN Processes messages received over the LIN Event driven ICM Mgr Monitors ICM link low level status Applies timeouts to transmitted messages Reprograms ICM hardware if errors are detected Every 50 msec PRMT Process Redundancy Management Task Responsible for effecting and maintaining synchronisation between redundant processors Every 100 msec approx Pr Rx Processes message received via PRP Applicable only when using ELIN Every 100 msec approx EDBserv x2 Manages communications with external databases via cached bloc
36. 2 3 1a an M4 earth stud connection is provided on the back plane metalwork This stud should be bonded to a good local earth using multistrand tri rated 1 5mm 21A green yellow earth cable with ring terminals for security HA028225 Chapter 2 Issue 2 Nov 03 Page 2 19 PROCESS SUPERVISOR HANDBOOK 2 5 4 Transparent Modbus Access TMA This feature allows the use of the Eurotherm iTools package to configure Model 2500 controllers without having to disconnect them from the Process Supervisor As depicted in figure 2 5 4 below the 2500s are daisy chained from the Instruments s Modbus Master port Exp 1 or the Profibus port I O via an EIA422 link The PC is connected to the Exp 2 port via an EIA232 link or to the System A port via an Ethernet link With the iTools package running on the PC the 2500s can then be configured by talking through the Process Supervisor Notes 1 In order for TMA to work the database must contain a Gateway file GWF with the same name as the database file dbf 2 If the Profibus port is used the 2500 unit s must support Profibus DPv1 3 Instead of using PC iTools via an occasional EJA232 link a SCADA facility can be used via a permanent EIA422 exp2 port or Modbus TCP link System A port 4 PC iTools can also be connected to the Modbus port but needs an EIA422 485 convertor For an occa sional link it is normally considered more convenient to use the CFG port on the fr
37. 5 1 Example wiring for watchdog relays in parallel Chapter 2 HA028255 Page 2 16 Issue 2 Nov PROCESS SUPERVISOR HANDBOOK 2 5 2 Processor module The processor module contains one user connection an RJ11 type plug for the connection of a configuration terminal for on line monitoring and minor configuration editing It is possible to configure a whole system from such a termi nal but is not recommended because of the complexity of most systems It is recommended that a Communications isolator be connected between the processor module and the terminal Fig ure 2 5 2a gives a pinout for such a unit Figure 2 5 2b shows cables for connecting the processor config port directly to a PC s EJA232 port both 9 way and 25 way versions Communications parameters should be set up as listed below from the Properties Connect to Configure connection menu Baud Rate N of data bits N of start bits Parity N of stop bits EIA232 Connections Communications isolator Processor Signal etc Port 1 Port 2 8 way 6 way RJ11 RX Input 3 TX Output 1 Signal ground 6 RTS Supply Supply UNIVERSAL INTERFACE CONVERTER Notes 1 For isolators with a DIP switch adjacent to Port 2 set all elements Off for EIA232 Comms 2 The RJ11 connector is in parallel with Port 1 Signals only not power 3 For recommended isolators and suitable made up cables ref
38. 8 2 1 Filter replacement 1 Remove the relevant processor module from the backplane as shown for the connection module in Chapter 2 of this manual 2 Undo and remove the six front panel securing screws A in figure 8 1 3 With the processor module vertical i e with its connector on the bench carefully lift the front panel away re leasing the ribbon cable connection as it becomes accessible Place the front panel in a static safe area ready for later re assembly 4 Remove the two jacking screws and place them to one side for later re assembly ensuring that the associ ated plastic washers are retained 5 Lay the module on one side and slide the lower panel containing the fan out such that the four 4mm 7mm AF fan securing nuts C are accessible 6 Undo these nuts and ensuring all fixings are retained remove the nuts and washers and lift the fan off its studs 7 Again retaining all fixings remove the fan filter and replace it with a new one 8 Replacing all the washers previously removed re fit the fan and secure it using the M4 nuts C 9 Slide the lower panel back into place carefully ensuring that the fan cable harness is not damaged in the process 10 With the processor module standing on its connector again re fit the two jacking screws 11 Re fit the ribbon cable connector to the front panel and re fit the front panel to the module ensuring that the jacking screws are
39. 8709 870A 870B 870C Unnamed blocks Cannot save compounds No root block GRF file write failed Compounds too deep Unused block deleted Unused GRF connection deleted Missing GRF block added Missing GRF connection added Unknown DBF GRF block mismatch Unknown DBF GRF connect mismatch DBF GRF file mismatch use FIX Table 6 6 2e Control config error codes 87xx 8 01 Object Overload 8B02 Text Overload 8B03 No Matching Step Name 8B04 No Matching Action Name 8 05 Step already Exists 8B06 Action already Exists 8 07 Link already Exists 8B08 Leave a Bigger Gap 8B09 Bad Time Format 8BOA File Read Error 8BOB File Write Error 8BOC File doesn t Exist 8BOD File not Open 8BOE Create Action 8BOF No Match with string 8B10 No More Matches 8B11 Match found in Transition 8B12 Match found in Action 8B13 Changed Are you sure 8B14 Link Already Exists 8 15 Illegal Chars Name 8B16 Action Did Not Compile 8B17 Fatal Memory Overflow Quit Now 8B18 Out of memory when compiling 8B19 Root action must be SFC 8BIA Invalid actions found during compilation 8BIB Invalid DB name 8BIC No database loaded 8BID Map is invalid 8901 8902 8903 8904 8905 8906 8907 8908 8909 890A 890B 890C 890D 890E 890F 8910 8911 8912 8913 8999 Network timeout Rejected by local node Rejected by remote node Not implemented Not active on local node Not active on remote n
40. It is however the responsibil ity of the installer to ensure the safety and EMC compliance of any particular installation 2 1 1 Installation requirements for EMC This unit conforms with the essential protection requirements of the EMC Directive 89 336 EEC amended by 93 68 EEC It also satisfies the emissions and immunity standards for industrial environments To ensure compliance with the European EMC directive certain installation precautions are necessary as follows 1 General guidance For general guidance refer to the Eurotherm Process Automation EMC Installation Guide Part No HG083635 U001 2 Relay outputs When using relay outputs it may be necessary to fit a filter suitable for suppressing conducted emissions The filter requirements will depend on the type of load 3 Routing of wires To minimise the pick up of electrical noise low voltage DC connections and sensor input wiring should be routed away from high current power cables Where it is impractical to do this shielded cables should be used with the shield grounded at both ends HA028225 Chapter 2 Issue 2 Nov 03 Page 2 1 PROCESS SUPERVISOR HANDBOOK 2 1 2 Installation safety requirements PERSONNEL Installation must be carried out only by authorized personnel HAZARDOUS VOLTAGES Caution In order to comply with the requirements of BS EN61010 the voltage applied across I O terminals may not exceed those terminals isolation voltage see Chapter 9 f
41. Normal Enable Enable gt 0000 2 0 Normal Enable Enable 20000 3 0 Normal Enable Enable 20000 4 0 Normal Enable Enable 20000 5 0 Normal Enable Enable 20000 6 0 Normal Enable Enable 20000 7 0 Normal Enable Enable 20000 8 0 Normal Enable Enable 20000 9 0 Normal Enable Enable 20000 10 0 Normal Enable Enable 20000 11 0 Normal Enable Enable 20000 12 0 Normal Enable Enable 20000 13 0 Normal Enable Enable 20000 14 0 Normal Enable Enable gt 0000 15 0 Normal Enable Enable 20000 Figure 5 6 3b Register table menu default Register Register and diagnostic tables only This column shows the Modbus address of the particular register The first register in the table takes its address from the Offset value given to the table via the tables list described above The remaining read only addresses follow on consecutively HA028225 Section 5 Issue 3 Jly 04 5 19 PROCESS SUPERVISO R HAN DBOOK 5 6 3 TABLES Cont Digital Field DP Format Width Digital tables only This column shows the Modbus address of the digital bit on that particular line of the table If the line contains a bitfield rather than a single bit the address shown is that of the first bit in the bitfield Mappings may be made for a single bit or for an 8 or 16 bit field according to the value defined in the Width parameter see later The very first bit address in the table takes its value from the Offset g
42. O m Om int ext 5 A D battery O OJ O m battery O OJ O m b ie ue system O O OO ep system O O OO ep a B t ep a vo ep J lb n out h out primary O standby primary O standby sync changeover sync changeover expl out n on desync desync Restart config Restart config Py out n ot hot s hot cold hot cold 2 eo Teo o b 4 test perm 72 wig batt 72 wg b halt O O duplex halt O duplex 24V 24V A A left pi ight processor An Invensys company An Invensys company Figure 1 3 Connect module left and dual processor modules centre and right on the backplane HAO28225 Issue 2 Nov 03 Chapter 1 Page 1 1 PROCESS SUPERVISER HANDBOOK 1 3 1 Typical applications The process supervisor is designed to control processing plants using distributed input output modules interconnected using networks A number of process supervisors can be networked together allowing thousands of I O points to be monitored and controlled 1 3 2 Features The main features of the process supervisor are as follows LIN A LIN based network using either ALIN or ELIN This allows communications with I O modules and the wider net work via either a daisy cha
43. SUPERVISO R HAN DBOOK 5 5 1 MAKE Cont 2 Parameter values Type in a value and press lt Enter gt to update the database Read only parameters do not accept new values The processor module automatically adds a following decimal point and padding zeros if needed but before a decimal point a zero must always be typed e g 0 5 not 5 Pressing lt Enter gt with the field selected before starting to type accesses a Full Description page for the param eter Figure 5 5 1d shows an example FULL DESCRIPTION Field PV Block PID_1 Type PID Value 80 1 Real32 Input SIM 1 0P Figure 5 5 1d FULLDESCRIPTION page for parameter example Field Block Type Read only fields Value Parameter value editable as for the Overview Read write Real32 Value type Real32 floating point number Read Only Input Defines the source of any connection to the parameter from another block as Block Tagname Output Mnemonic A blank field means no connection To make or edit a connection type in the source block tagname and output mnemonic e g SIM 1 OP or SEQ DIGOUT BIT3 then press Enter Invalid data is beeped and is not accepted The field is not case sensitive To delete a connection type space then press Enter Read write Note See CONNECTION TYPES below for information and advice on types of database connections 3 Parameter units Type in a value and press Enter All other related un
44. Servers maximum Number of connections Control database size maximum 2048 50 28 32 1024 512 8 1024 400 kByte Notes 1 Apart from database memory sizes the figures above are default maximums and are the recommended limits for typical situations Subject to note 2 below it is possible to exceed some of the above maxima although if a database with more resources than the default maximum is loaded then the maxi mum is set to the new value and there may then be insufficient memory to load the entire database In such a case the connections disappear first FEATTs are not subject to this problem since when a database is saved there are not normally any FEATTs present so the default maximum cannot be overrid den 2 The EDB maximum must not be exceeded If it is some EDBs will malfunction and this is likely to affect the LINtools VIEW facility Continuous database performance To be issued later Sequence Control Resources Sequence memory Program data SFC Resources N of independent sequence tasks SFC actions Steps Action associations Actions Transitions 256 kBytes 512 kBytes AO simultaneously active 200 including root SFCs 640 2400 1200 900 028255 Issue 04 Chapter 9 9 5 PROCESS SUPERVISOR HANDBOOK 9 2 ORDER CODES 9 2 1 Instrument order code Base Processor 1 Processor 2 type Comms Comms toaox 1
45. Stead i Y Process Supervisor hardware fault hardware Off The relevant comms system is not running Not running System A ELIN System ELIN I OA ALIN Profibus Table 4 8 1 System and i o LED interpretations and error weights 028225 Chapter 4 Issue 2 Nov 03 Page 4 11 PROCESS SUPERVISOR HANDBOOK 4 8 2 Profibus Examples Figure 4 8 2a is a simplified version of the cabling in figure 2 5 above Potential cable breaks are shown at points 1 2 and 3 and the resulting reactions are given in table 4 8 2a Figure 4 8 2b and table 4 8 2b below give similar information for an alternative cabling scheme Break 2 Break point Processor reaction VO unit 1 VO unit 2 Break 1 Processor 1 P can see no slaves Processor 2 S cannot see the primary Both report faulty network I OB LEDs flash red Processors change over Processor 2 P now sees all slaves and reports OK LED steady green Processor 1 S cannot see Processor 2 and reports Faulty network LED flashes red Units desynchronise with processor 2 the primary K Break 1 Processor 1 P can see some slaves and reports faulty slave LED flashes green Processor 2 S cannot see the primary and reports faulty network LED flashes red Units desynchronise with processor 1 remaining the primary Break 3 Processor 1 P can see all slaves and reports OK LED steady green Processo
46. The Configurator program is mainly for adjusting configurations on site usually to accompany modifications to the processing plant The T500 550 LINtools Product Manual HA082377U999 should be referred to for details of the configuration procedure using the LINtools package The Configurator employs the standard LIN block structured approach The LIN Product Manual gives full details of the software function blocks available for strategies and how to configure their parameters The Configurator can also be used to load start stop save and monitor databases and to perform various filing op erations 5 2 CONFIGURABLE ITEMS The configurable items depend on whether the database or Modbus communications is to be configured In either case it is a menu item selection procedure The LINtools package by comparison offers an icon based drawing capability Configuration of the database consists of carrying out one or more of the following Installing function blocks in the control strategy MAKE Creating duplicates of existing blocks COPY Deleting blocks DELETE Inspecting and updating blocks INSPECT Assigning LIN names and node addresses to external databases NETWORK Accessing the Utilities menu UTILITIES from which the user can START and STOP programs SAVE and LOAD databases and FILE pages APPLY or UNDO changes and Access the ELIN setup page CN ES Note External databases EDBs are databases runnin
47. a deeper level press Escape to return to a higher level Note that editing a database during runtime is possible but is not recommended Stopping the database is described in section 5 5 6 028225 Section 5 Issue 3 Jly 04 5 7 PROCESS SUPERVISO R HAN DBOOK 5 5 1 MAKE Cont 1 User defined names Type in a name 8 characters max and press lt Enter gt to overwrite existing data To insert characters locate the cursor at the character to follow and type the insertions A beep warns that excess characters have been typed To abort the current entry and leave the database unchanged move the cursor to a field above or below the cur rent field before pressing lt Enter gt or press the lt Escape gt key Note Remote database names entered in the DBase field must be prefixed by an equals sign which is included in the character count Pressing lt Enter gt with the cursor on the first character of the Block or DBase fields before starting to type ac cesses a Full Description page Figure 5 5 1c shows an example This page gives general information about the block and has a common format FULL D ESCRIPTION Block 01 Type ANIN Refresh rate 0 1040 Server number 2 DBase Alpha Rate ms 10 Execute time 1234 Block Type Refresh rate Server number DBase Rate ms Execution time Figure 5 5 1c FULL DESCRIPTIO N page for block exa
48. address etc is entered using data obtained from the network administrator REMOTE SUBNET NODE LIST Allows the user to enter the IP addresses of all the nodes with which it is required to communi cate The PR section of the network unh file Once all the required entries have been made the ESC key should be operated A confirmation message asks if the network unh file is to be updated If Y the file is updated and a power cycle is requested CROSS SUBNET WORKING With All Subnet Enable set OFF default the instrument will not communicate ELIN cross subnet This can be overridden in the network unh file by setting All Subnet Enable to ON This defines the behavior when the Proc ess Supervisor powers on The ability to communicate cross subnet can be modified at run time by using the Options AllSubnt bit in the instrument s header block Set to TRUE this bit enables cross subnet working When set to FALSE cross subnet working is disabled Note This bit may be set FALSE remotely from a cross subnet connection If this is done communications will be lost and it will thus not be possible to reset it to TRUE from the cross subnet connection 5 5 7 ALARMS Select ALARMS to view the currently active alarms in the instrument Move the cursor up and down the list press Enter to acknowledge an individual alarm Press I to inspect the block containing the alarm Section 5 HA028225 5
49. dual synchronised processors the terminal PC must be linked to the primary processor not the secondary 2 Itis recommended that if a mains powered PC is to be used that it be isolated from the Processor Module by a Comms isolator For details section 2 4 2 Processor Module should be referred to 5 3 2 Setting the control efficiency If the Configurator is to be used without the database running continue at section 5 4 Running the Configurator with the database running can affect the control efficiency of the instrument The control efficiency is the percentage of CPU time spent on control tasks i e updating function blocks Any diversion from this task will cause a fall in control efficiency 100 efficiency can never be attained because there will always be minor ancillary tasks occupying the CPU s time but under normal control activity with no major diversion typical control efficiency will range from 80 to 95 How much the efficiency falls due to diversion to configuration tasks depends upon whether the Supervisor is set up as non redundant or redundant NON REDUNDANT SIMPLEX SYSTEM The processor spends 80 of its time updating blocks in the control strategy leaving a fixed 20 available for con figuration tasks REDUNDANT DUPLEX SYSTEM The primary processor spends up tp 70 of its time updating blocks in the control strategy The synchroniation task leaves the configurator with a small percentage of time in whi
50. during the above sequence the test continues with the Primary Standby and Du plex LEDs flashing and at the same time the following LEDs being switched on and off one after the other in an endless loop int sysA sysB i oB i o A ext rll expl tx exp2 tx 2 rx expl 112 This loop is stopped and the LED sub menu redisplayed by typing 2 CR but it should be noted that it will con tinue until its next conclusion rl2 off which can take over 20 seconds 028225 Section 8 Issue 2 Nov 03 8 13 PROCESS SUPERVISOR HANDBOOK 8 4 6 Manual set up This screen is accessed by typing 4 in the main menu Level 1 0 Quit 1 SYS Ethernet I O Arcnet Two exp serial lines 2 SYS Ethernet I O A Arcnet I O B Profibus Two exp serial lines 3 SYS Ethernet I O B Profibus Two exp serial lines 4 SYS Ethernet Redundant profibus Two exp ArcNet line bar ies Selection 8 4 7 Automatic set up This screen is accessed by typing 5 in the main menu then when ready CR The carriage return initiates the first of a number of tests described below Whilst the test is in progress the message testing appears When the test is complete a further line appears allowing the user to quit the test proce dure to repeat the previous test or to move to the next test testing lt ESC gt to quit lt ENTER
51. eed 6 5 teinte meii 1 3 B2 cT 3 5 LED wdog eee 3 8 4 5 4 9 System 3 5 4 9 Relay 2 16 System IMOHITOIS a ENAT 6 11 R sta s 6 5 Re thy etico 2 5 2 7 2 7 cat i 5 1 a 8519 Tables 4424424111 5 18 And CORTE 2 8 Talk thru 2 20 whe dk 2 15 Belen ces ron B 2 16 Tepidd ta orien eR ene ae 4 2 Terminal configurator restrictions 2 19 Termination assemblies 2 8 Test start une Eme ute ees 3 9 Time Maintaining during power down 2 15 To achieve synchronisation 3 7 4 8 TImeoUt oer ee UM one tens 5 17 TMA ete cet titer ons 2 20 TOD DIAG x ise eo tes 6 12 Transparent Modbus Access 2 20 TUNING trier de 7 5 Index HA028225 4 Issue 3 Jly 04 Inter Company sales and service locations Australia Eurotherm Pty Limited Unit 10 40 Brookhollow Avenue Baulkham Hills NSW 2153 Telephone 61 2 9634 8444 Fax 61 2 9634 8555 e mail eurotherm eurotherm com au ht
52. established Flashing red green Communications possible but not taking place usually due to a desynch request 028225 Chapter 6 Issue 2 Nov 03 Page 6 5 PROCESS SUPERVISOR HANDBOOK 6 2 5 ICM FAILURE Cont ACTION IN THE EVENT OF ICM FAILURE In the event of an ICM failure the processors desynchronise The control strategy must be designed to present the supervisory system with an appropriate alarm to annunciate this state E G use the RED_CTRL block s ICM_Ok status bit If the ICM does fail the secondary processor module should be replaced If this solves the problem re synchronise the processors If the fault persists the running primary processor module is the most likely cause and should be replaced Initially the original secondary should be re fitted as it is unlikely to be faulty and will still retain the cur rent database in memory with the parameter values existing at the time of desynchronisation The faulty primary should now be removed this causing the secondary to take over as sole primary but with a stopped database If ap propriate restart the existing database by powering down and then up again Otherwise reload a default database and restart it in the new primary This last option is a cold start and requires manual supervision of the plant during the transition Note A fault in the backplane is a possible but unlikely cause of ICM failure 6 2 6 LIN failure This occurs when a processo
53. for batch load operations e g loading or unloading an SFC Event driven 23 Bgnd scan Collates alarm information Performs database checksum testing Event driven 24 Idle Null task Provides environment for CPU execution whilst no other tasks run Note 1 Every 4 msec for units with sofware version prior to version 4 1 Note 2 or less often subject to CPU loading Table 7 1 3 Task sceduling Event driven Chapter 7 7 2 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 7 2 USER TASKS 7 2 1 Terminology USER TASK A user task is an element of strategy i e a piece of software programmed into the instrument by the control engineer which is nominally associated with an element of control SERVER A server is a fixed software task within the Process Supervisor that executes a user task or processes cached blocks 7 2 2 User task servers SERVER INTERACTIONS There are six servers within the Process Supervisor one for each of the user tasks and two for the cached blocks see table 7 1 3 The servers are prioritised repeat rate driven and fully coherent as described in section 7 4 The Proc essor Supervisor s block structured database is completely compatible with that of the T100 T1000 instruments and supports cached blocks in the same way Server has the highest priority and server 6 the lowest Interruption of one server by another of higher priority has alre
54. improvement The specifications in this document may therefore be changed without notice The information in this document is given in good faith but is intended for guidance only Eurotherm Limited will accept no responsibility for any losses arising from errors in this document PROCESSS SUPERVISOR HANDBOOK PROCESS SUPERVISOR HANDBOOK LIST OF CHAPTERS Section Title Issue level rod c r Ee 3 Chapter 1 Introduction tsetse 2 Chapter 2 Installation 2 Chapter 3 User interface 2 Chapter 4 SIAM Pty od od estia fes dO INI aie 2 Chapter 5 Configuration oed eee tet e od Det 3 Chapter 6 Error conditions and diagnostics 2 Chapter 7 Task Scheduling and 2 Chapl r 9 Service enro men 2 Chapter 9 Specification and order codes 8 3 EFFECTIVITY This manual refers to Process Supervisor units fitted with Version V4 1 software See The Modbus Profibus manual for details of serial communications 028225 Issue 3 04 Section i Page i PROCESS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page GLOSSARY OF TERMS 1 9 CHAPTER 1 INTRODUCTION 1 1 T T MANUALE CONTENTS i e
55. key to continue Typing any key returns the UTILITIES menu An invalid filename specification aborts the save and an error message is sent e g Save failed Invalid device Notes 1 When you START a database in RAM it is automatically saved to the file in E drive called filename DBF where filename is indicated in the filename RUN file It is then reloaded and started 2 Modifications to a control database are carried out on the RAM image only not directly to the DBF file in E drive They are copied to E drive overwriting the existing DBF file automatically as you restart the database or when you do a SAVE operation Section 5 028225 Page 5 14 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 5 6 UTILITIES Cont LOAD UTILITY Retrieves a control program from a specified memory area and loads it to the processor RAM Note that LOAD can not be performed during runtime Select LOAD from the UTILITIES options menu the default filename specifica tion E T940 DBF is displayed Edit the specification if needed to alter the filename or its source as described in SAVE utility above then press Enter After a short pause the processor signals completion as described for the SAVE option Typing any key returns the UTILITIES menu An invalid filename specification aborts the load and an error message is sent e g Load failed File not found FILE UTILITY Permits access to the proc
56. located in their apertures in both back and front panels Secure the front panel using the six screws A previously removed Note This final part of the re assembly is non trivial If a non powered back plane is available it is easier to secure the processor module onto the back plane before the front panel is fitted This ensures that the jacking screws do not move during the fixing of the front panel 12 If not already re fitted re fit the module to the backplane and secure using the jacking screws ensuring that the connector is correctly mated before tightening the screws a few turns at a time each to a final torque of not more than 2 5 Nm Section 8 HA028225 Page 8 2 Issue 2 Nov PROCESS SUPERVISOR HANDBOOK 8 2 REPLACEMENT PROCEDURES Cont Plastic washer 4 places Battery Board Figure 8 2 Processor module part explosion 8 2 2 Chassis Fan replacement Note When fitting the fan ensure that it is oriented correctly with the air flow direction arrow pointing towards the filter i e the airflow is out of the unit The arrow is to be found on the edge of the fan body adjacent to the wire aperture 1 Prepare the module by carrying out steps 1 to 4 of section 8 2 1 above 2 Lay the module on one side and slide the lower panel containing the external fan out disconnecting the fan connector D in figure 8 2 above as it becomes accessible 3 U
57. other in case of failure In such a case one processor unit normally the left hand one is called the primary and the other the secondary The secondary tracks the primary so that it can take over with minimum disturbance to the controlled system Non Redundant simplex mode is where a there is only one processor or b there are two processors fitted which act independently of one another either intentionally or because one has failed Redundant non redundant mode is selected using the options switch SW2 on the back plane as shown in section 2 4 of this manual START UP MODES The required start up mode is selected using the eight way rotary switch located near the bottom left of the processor front panel This allows Hot cold Cold or Test to be selected Each start mode has two positions on the switch 180 apart Figure 4 2 1a below shows a simplified flow diagram for the different modes 4 2 1 Hotstart Hot start means that the instrument re starts from where it stopped running A suitable time period Cold Start Time is configured in the root block of the control data base and if this period is exceeded after the data base stops running then a hot start is not permissible The Cold Start Time for any process can be defined as That period after the data base stops running within which the database can be restarted from where it left off without degrading or endangering the control pr
58. press the key and type in the block name field name from which the connection is to be made Note See CONNECTION TYPES below for information and advice on types of database connections 7 and four digit combined hexadecimal status fields Hex fields are marked with a gt sign and have the same format and significance as those found in LINtools specifica tion menus The digits show the logic states of a corresponding set of parameters up to four per hex digit To edit the field directly type in new values then press lt Enter gt Alternatively press lt Enter gt to display a Full Description page listing the parameter TRUE FALSE states and edit this list as described for Bitfields above CONNECTION TYPES IN A PROCESSOR MODULE DATABASE There are three types of connection used in a processor module database local connections connections writing to a cached block and connections from a cached block to a local block The following explains how and when they are evaluated 1 Local connections These are connections between two blocks that are both local to the processor module database The connection is always evaluated immediately prior to the execution of the destination block s update procedure regardless of whether the source data has changed between iterations With this sort of connection any attempt to write to the connection destination is immediately corrected by the next connection ev
59. same format as for the COPY option described in section 5 5 2 Select a block and press Enter The block and any connections from it are deleted and the main menu returns to the screen Notes 1 The control database must be stopped otherwise selecting DELETE results in an audible warning and no action Stopping the database is described in the UTILITIES option described in section 5 5 6 2 A block cannot be deleted unless its input connections have been cleared Section 5 HA028225 5 12 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 5 4 INSPECT Allows blocks in the control strategy to be inspected and updated Select INSPECT from the main menu to display all the blocks in the control strategy in the same format as for the COPY and DELETE options already described Select a block and press lt Enter gt to display its overview page ready for monitoring updating Pressing lt Escape gt returns the INSPECT display where other blocks can be selected for inspection Press lt Escape gt again to return to the top level menu 5 5 5 NETWORK Allows block databases to be assigned names and node addresses on the LIN Local Instrument Network so that they can be configured as cached blocks and run in a remote instrument The overview page of the cached block DBase field specifies the remote database name Note It is good practice when using cached blocks to cache at least one block in each direction Th
60. snapshot to the higher priority task In this way the values passed on are always the last set of coherent values from a complete task ex ecution CONNECTIONS INTO THIS TASK FROM OTHER TASKS IN ANOTHER IN STRUMENT Connections between nodes are effected by the use of cached blocks The process of cached block transmission and reception at the destination end is coherent for all the data within that block At the destination end the cached block exists on a cached block server Connections from this cached block to other blocks effectively become inter server connections within the same node the coherence of which is guaranteed as described in Connections into tasks immediately above Chapter 7 HA028225 Page 7 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 7 4 1 DATAFLOW BETWEEN TASKS Cont CONNECTIONS OUT OF THIS TASK TO ANOTHER NODE This type of connection results in data flow that is not coherent because the data is transmitted across the network as individual field writes rather than as whole block updates If coherence is required the block s can be cached in the opposite direction via an AN_CONN block for example This is illustrated in Figure 7 4 where block A coherently connects to block B across the LIN via the AN_CONN block bold lines but the connection is non coherent when routed via cached block B Coherent block Node 2 update AN_CONN cached Non coherent field write Y Figure
61. teet eigens 6 12 MODBUS 94xx 6 16 ecco a re eaten 6 5 Object system 85 6 15 Input ii tee PRG HRS 5 9 PCLIN PC I F 6 16 INSPEC T asec there cette eene 5 1 5 13 5 21 Sequence database 8 6 15 Installation Sequence runtime 8 6 15 Category scandens e et en tende 9 1 Structured text 8Dxx 6 16 Installation safety requirements 2 2 T1000 menu system 90xx 6 16 Inter server connections 7 6 Trend system 86xx 6 15 Internal battery 2 15 KOC 9BXX wkend te eene nee 6 16 address 3 2 0 0 sii ie 5 3 5 16 Conditions diagnostics 6 1 IP Subnels nett EU 5 4 Displays ates 6 10 Fatal vow ation a 6 12 K 040 6 1 6 13 Ethernet MAC address 5 3 BORING MA see deh att ese Eurotherm Project Studio 2 19 L Exec tior times ee 7 5 Expi exp2 LEDS tae 3 5 4 9 Labelling i 2 oni reete 2 3 External battery connection
62. valid Auixiliary power input failed backup ext External battery power valid Off until start up External battery power faile complete Internal battery power valid Off until start up backup int Internal battery power failed complete Power B Alarm active Alarm not active Alarm active Alarm not active System A communications valid System A System A communications hardware failure System A communications cable fault System A communications not in use System B communications valid System B communications hardware failure System B communications cable fault System B communications not in use A communications valid A communications hardware failure A communications cable fault A communications not in use System B B communications valid Flashing Green off Remote unit fault Profibus comms only B communications hardware failure B communications cable fault B communications not in use Exp1 Tx Rx Intermittent yellow Communications taking place Exp2 Tx Rx Intermittent yellow Communications taking place This CPU is primary Primary This CPU is not primary Powered up but no database is running This CPU is secondary and synchronised Standby This CPU is not secondary synchronised Synchronisation process in progress CPU not in reset wdog CPU in reset Power up sequence in progress Redundancy communications valid Duplex System in non redundant mode Inter
63. 100 metres max Final hyphen is connector boot colour default Consult factory for other colours Profibus in cubicle cables 1x RJ45 connector and ferrules for screw terminals eee S9508 5 1RJA45 xxx RJ45 connectors both S9508 5 2RJA5 xxx xxx cable length in 10 cm increments to 100 metres max Final hyphen is connector boot colour default Consult factory for other colours Configuration terminal cables RIV to 9 way D type 3 onere etr teens DN026484 RJ 10 25 way D type vase esi ela eS To be issued later Cable accessories ALIN terminal mounted line terminator eese LA082586U002 ArcNet MODBUS line terminator RJ45 sess CI026528 Profibus line terminator RJ45 sess nnne CI026529 Feed through adapter 5 250407 Shielded RJ45 connector unassembled 250449 RJ45 connector assembly handtool esee Consult factory ALIN AteNet thub sich hee here ep Ea at o ERR REA I Peso Rath 59576 28255 Chapter 9 Issue 3 04 Page 9 7 PROCESS SUPERVISOR HANDBOOK 9 3 COSHH Product BACK UP BATTERIES Part numbers PA250331 mounted on circuit board assembly AH249182 Nickel Metal Hydride batteries PA261437 mounted on circuit board assembly AH261438 HAZARDOUS INGREDIENTS
64. 14 84 7 Automatic SeFUD rte rette tee Ete REDE EE ERU EIE GRE ONS 8 14 WATCHDOG RELAY TEST n urs tt ett totes 8 14 RLI RELAY TEST etd 8 15 REZ RELAY 8 15 COMMUNICATIONS HARDWARE CHECK 8 15 8 4 8 The S Monitor 5r re ree ee epe e ede 8 16 S MONITOR 55 8 16 en 8 16 denote a 8 16 DISPLAY BASIC MACHINE STATUS 8 17 DISPLAY EXTENDED MACHINE STATUS 8 17 DIAGNOSTICS poc nee Pep LR ie torto di ete siegt 8 18 MEMORY STATUS rer ebd tee Pe ode etes 8 20 SHOW 8 20 DATE i Ir dee cde PER Te 8 20 CHAPTER 9 SPECIFICATION ABD ORDER CODES 9 1 SPECIFICATION t tei ebrii 9 2 9 1 1 General specification 55124 e rere dee ette dea e 9 2 9 1 2 Backplane specilication eee ert eee 9 2 9 1 3 Connect module specification 9 3 9 1 4 Processor Module specification 2 9 4 9 1 5 Software specification 2 2 9 9 5 9 2 ORDER CODES ec 9 6 9 2 1 Instrument order code 9 6 9 2 2 5
65. 16 Issue 3 Jly 04 PROCESS SUPERVISOR HAN DBOOK 5 6 MODBUS CONFIGURATION Figure 5 6 shows the Gateway menu Note The resident Modbus configurator works in a similar way to the Modbus configurator in the T500 LINtools package Refer to the 7500 T550 LINtools Product Manual Part No HA082377U999 for more information GATEWAY MODBUS configuration gt MODE Operating mode SETUP Serial line TABLES Register amp bit configuration UTILITIES File Load amp Save Figure 5 6 Gateway menu 5 6 1 MODE Sets the operating state of the instrument to Slave or Master Selecting MODE pops up a menu showing the current mode Slave by default as shown in Figure 5 6 1 Select a different mode if required MODE Operating mode Mode gt Slave Master Figure 5 6 1 MODE menu Note Master mode is not available with this release of software 5 6 2 SETUP Displays parameters for serial link operation The items are not editable Select SETUP to see a menu of four items Baud rate Parity Stop bits and Time out in master mode plus a fifth item Slave No if slave mode has been configured The user can select new values for the parameters but these new values are not saved Baud rate Displays the current setting Highlight and Enter this item to see a menu of possible baud rates 110 150 300 600 1200 2400 4800 9600 and 19200 Parity D
66. 232 Configuration sub system sub system Terminal Terminator b ELIN connection Process Process Figure 2 5 Typical overall connection diagrams Chapter 2 HA028255 Page 2 8 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 5 1 Connect module The RJ45 connectors on the front panel can be wired for ELIN ALIN Modbus or Profibus use according to specifi cation at time of order The pairs of connectors on the left hand side of the module are assigned to the left hand proc essor the right hand connectors to the right hand module Each pair of connectors except system A B is wired in parallel to provide for easy daisy chaining Plug in modules to provide biassing components to terminate the transmission line are available from the manufac turer Such terminators are required only at the final node of the transmission line Note Terminators are not required for ELIN systems Process Supervisor gn cyrotHerm Connect 22 suite Modbus Master Modbus Slave Lo UJ 24 left processor right processor Figure 2 5 1a Connect module front panel HA028225 Chapter 2 Issue 2 Nov 03 Page 2 9 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont COMMUNICATIONS CONNECTORS Figure 2 5 1b shows the connector pinouts for Modbus EIA422 or EIA485 Profibus and LIN standards For the pinout for the proc
67. 5 2 NON REDUNDANT SIMPLEX SYSTEM 5 2 REDUNDANT DUPLEX SYSTEM 2 5 2 5 4 RUNNING THE CONFIGURATOR 9 5 3 5 4 1 Initial menu Gccess s en 5 3 IP SUBINEIS estote de RIDE NN INI Ie 5 4 5 4 2 The Initial menus rte WR nre ied ete 5 5 5 4 3 Quitting the terminal emulation program s 5 5 5 5 DATABASE CONFIGURATION 920000 5 5 oss ate RI RAN 5 6 BIOCK OVERVIEW ete uten ter mu 5 7 CONNECTION TYPES IN A PROCESSOR MODULE DATABASE 5 11 55 2 CORY 5 12 5 5 3 aes eee 5 12 ER INSPECT E eMe 5 13 5 5 5 INETWONRK veh hated 5 13 5 5 0 UTIHITIES rere a de 5 14 START STOP UTILITIES tete ede tetas 5 14 SAVE UTILITY ne rere HE ertt 5 14 LOAD MOTIMITY e ein mah wdbelacnea se 5 15 FILE UTIL se ees eet bonis deze ete sede 5 15 APPLY UNDO UTILITIES 202 2 49 5 15 EHN SETUP 2 asi tat edet eee 5 16 2 927 ALARMS voee esca US cee sates ee teo eode 5 16 5 6 MODBUS CONFIGURATION 2 2 retten
68. 7 4 Coherent and non coherent data flow across network HA028225 Chapter 7 Issue 2 Nov 03 Page 7 7 PROCESS SUPERVISOR HANDBOOK This page is deliberately left blank Chapter 7 HA028225 Page7 8 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 8 SERVICE This section describes the regular preventive changing of filters fans back up batteries etc and shows how to re place the flash memory card Details of the M monitor and of the S monitor are also included For details of how to update the Profibus board and how to change the unit s system software boot ROM and librar ies please contact the nearest manufacturer s service centre Ais Caution All circuit boards associated with this unit are susceptible to damage due to static electrical discharges of voltages as low as 60V All relevant personnel must be aware of correct static handling procedures 8 1 PREVENTIVE MAINTENANCE SCHEDULE The following periods are recommended to guarantee maximum availability of the processor unit for use in what the manufacturer considers to be a normal environment Should the environment be particularly dirty or particularly clean then the relevant parts of the schedule may be adjusted accordingly For example the fan filter may need re placing more frequently than every two years if the unit is located in a dusty area The following are recommended 1 A visual inspection of the chassis mounted fan should be made
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70. 8 29 05 01 Baud 12000 kBits s Cyclic ramp itvl1 100 ms TQUI 9 tBit Acyclic ramp itvl 2000 ms TSET 16 tBit Min TSDR 11 tBit Max TSDR 800 tBit TSL 1000 tBit TTR 22923 tBit GAP update 10 cycles Min slave itvl 0 1 ms Protocol error Data ctrl time 200 ms Poll timeout 500 ms Error location COM flag not set Protocol cycle 1 ms Bus errors Watchdog ctrl 1000 ms Rejected telegrams D down load amp activate HAO28225 Issue 2 Nov 03 Section 8 Page 8 11 PROCESS SUPERVISOR HANDBOOK 8 4 5 DIAGNOSTICS MENU Cont PROFIBUS TEST Cont SLAVE DATA SCREEN Network 1 Node 4 not activated fault Id 04B4 IOS Dpvl Yes OUT Type Len Idx 2 IN Type Len Idx 2 Cyc Cyc ontl 116 1 0 4500 1 ontl 116 d 0 4000 2 rm sp 1 1 0 0 2 101 32 1 0 0 3 ModiPV 2408 8 5 0 132 4 4 5 5 6 6 7 7 8 8 1 ont2 116 1 0 6000 1 ont2 116 1 0 100 2 2 3 3 4 4 5 5 select S array scroll download amp activate copy node setup X remove node digit number address entry P A paste to all sp view master other popup menu Note Positioning the cursor under a field and pressing any key except those listed at the bottom of the screen for example picklist of available entries appears The required item is entered by moving the cursor to it by means of the up down arrow keys and pressing Enter
71. 9 1 Saver ML dE 7 3 6 1 6 10 6 18 222 Power Server number 8 5 8 Fail 6 5 SE TU Pitas s ettet eas 5 17 5 21 LEDS oon uu ier MCI a ant SFG disable etnies 2 7 e t LT 3 3 4 9 ose DUO 6 12 Supply FUSES 2 15 3 3 Simplex mode 4 1 Power self tests 6 10 6 18 Dee pune ene rere Primary Slave 5 17 5 19 LED 3 6 6 5 Spare parts nie e etes 9 7 ERE Specification SYNCH te tette 6 5 Unsynch state 4 6 6 5 Connection 9 3 General repe bands 9 2 Primary secondary Processor Module 9 4 Changeover 6 6 6 12 Po qud cap it et ee 9 3 Criteria npe 4 7 c MED 9 5 Priorities task sentent 7 1 MEHR ST user algorithms 2 2 1 3 Processor module 3 Standby LED icis 3 6 4 8 6 5 Failure modes eee 6 4 5 1 5 14 Front pariel ec 3 1 4 5 6 2 Start bits 2 17 Front panel eese denies ot ee 6 3 Ho Specification wesc ies 9 4 Mods 3 9 4 1 Profibus 5 27 Redundancy decisions e 4 52 Redundant mode worki 4 11
72. BS EN61326 2002 02 BS EN61010 1 A2 1993 To IEC1131 2 section 2 1 3 0 075mm peak amplitude1O to 57 Hz 1g 57 to 150 Hz Power Requirements Main supply Surge Current 24 dc nom 18 to 36Vdc at 50W per processor module maximum Two supplies can be connected per processor module to ensure continued operation should one supply fail 8A max Caution If the supply voltage drops below 18V during start up as a result of current limiting for example the processor will fail to start It will then attempt a re start causing the unit to enter a repeating cycle Damage will be caused to the unit if it is left in this state for more than 30 mins Backup supplies External option Internal option Fusing 24 supplies External batteries 2 4 to 5Volt battery Typical drain per processor 300 pA at 3 4V Nickel metal hydride battery board When fully charged this maintains the real time clock for 72 hours min 3A Type T in each positive supply line 0 5A Type T in each positive supply line 9 1 2 Backplane specification General Switches SW1 SW2 segment 1 SW2 segment 6 SW2 segment 5 Safety earth connection ALIN address Watchdog retry trip and try again mode Redundant non redundant mode select duplex simplex Modbus select By M4 earth stud on right hand flange of the backplane Caution Neither the positive nor the negative supply line may exceed 40V peak with respect to Safety Earth po
73. CPU communications failed Table 3 1 LED functions Chapter 3 28225 3 2 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 3 2 POWER MONITORING LEDS Power A GB 24V 0 int ext battery Figure 3 2 Power monitoring LED group This group of LEDs located near the top left of the processor module front panel shows the status of the power in puts wired to the Connect module and of the internal battery 3 2 1 AandB For each processor two independent sources of 24V power A and B can be wired to the Connect module The LEDs labelled A and B illuminate green if power supply inputs A and B respectively are greater than 14V All sources must be fused 3 A type T in the positive supply line 3 2 2 ext Each processor unit can be backed up by an external battery wired to the 8 way terminal blocks on the Connect mod ule This maintains the data in the real time clock for a period that depends on the Ampere hour Ah rating of the battery Typical load currents 200 at battery voltage of 2 4V and 300 at 3 4V Once the start up sequence is complete the ext LED illuminates continuously green if the battery voltage is greater than approximately 2 6V and 24V supply power is available When 24V power is not available the LED is not illuminated External battery supplies must be fused 0 5 A type T in the positive supply line 3 2 3 int A further 72 hours minimum back
74. CY DISABLE ee 2 7 Cont Section i HA028225 Pagei 2 Issue 3 Jly 04 PROCESSS SUPERVISOR HANDBOOK LIST OF CONTENTS Cont Section Page 2 5 CONNECTIONS AND 2 2 8 2 51 module ee 2 9 COMMUNICATIONS CONNECTORS 2 10 ELUN CONNECTORS pinia ether ee 2 11 AUN CONNECTORS oieri rete e tee tee ie 2 12 o oce uo 2519 ams Eidos ce 2 13 ALINSAUBS PASSIVE te grees pe te 2 14 DAISY CHAIN LAYOUT eren nter re 2 14 ec ELE 2 14 DC SUPPLY WIRING 2 vere tete P i ae e tdeo 2 15 RELAY WIRING pee Re Severs eee AAs ote s ORARE LE 2 16 2 5 2 Processor module etie o RH UR ees 2 17 CONFIGURATION OF CONTROL STRATEGIES AND SEQUENCES 2 19 TERMINAL CONFIGURATOR RESTRICTIONS 2 19 2 5 3 Safety earth connection 2 19 2 5 4 Transparent Modbus Access TMA 2 20 CHAPTER 3 USER INTERFACE 3 1 INTRODUCTION e eR e EO DR 3 1 3 2 POWER MONITORING 1 5 3 3 CENE Ne MM MU 3 3 REAPER 3 3 sa e
75. E 5 1 5 15 5 21 Functions sisi E SONT pes 5 19 e Le 5 11 3 3 LOOP te 7 3 G M Gateway mernu 5 17 MOHIESIL 8 7 8 20 H 4 10 6 11 MAC address se 5 3 Halt Swich 4 eei be one ters 3 8 Maintenance 8 1 Handling precautions 2 2 2 3 5 1 5 6 5 21 Hardware layout 8 6 8 7 Manual tuning 7 5 Health monitoring 1 2 MDB SWIICR enn reete eee 2 7 Hexadecimal fields 5 11 Misuse of 2 2 3 9 6 7 Hot Gold start niece 3 9 Hyperterminal eese 5 3 Index HA028225 Page 2 Issue 3 Jly 04 PROCESS SUPERVISOR HAN DBOOK M Cont R Modbus REDGThL ie eke eet a 6 12 Configuration 5 17 Redundancy Enable Switch 0 1 2 1 44 4 4201 40 2 7 Control block ortos teet eene 6 12 Enable switch location 2 5 Decisions 4 11 5 1 5 17 5 21 Enable switch eene 2 5 2 7 Module removal replacement
76. ED SYSTEM LED Accessed by selecting 2 from the diagnostics menu this page allows the two battery LEDs and the Duplex LED to be exercised individually I O LED Accessed by selecting 3 from the diagnostics menu this page allows the Comms panel system A and B and i o A and LEDs to be exercised individually SERIAL LED Accessed by selecting 4 from the diagnostics menu this page allows the Comms panel exp1 and exp 2 Rx and Tx LEDs the Alarm panel rll and rl2 LEDs and the Primary and Standby LEDs to be exercised individually Note Setting the rll or rl2 LED on does not switch the associated relay on Switching 11 or rl2 on in the watchdog menu above does cause the associated LED to be illuminated Section 8 028225 Page 8 18 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 8 S MONITOR DIAGNOSTICS MENU Cont WRO Accessed by selecting 5 from the diagnostics menu this redundancy control monitor page displays the following information TOT Ilock wr0 TEES Level 2 0 Quit 1 Bit 5 Reset minor fault 2 Bit 2 A request clocks 3 Bit 1 A Ok 4 Bit 0 A Req Primary mr Selection READ INPUT STATUS Accessed by selecting 6 from the diagnostics menu this page displays the following information lt DISPLAY gt Y y N y Y C
77. Engineering utilities ALARMS Current Alarms Figure 5 5 Configurator Main menu 028225 Section 5 Issue 3 Jly 04 5 5 PROCESS SUPERVISO R HAN DBOOK 5 5 1 MAKE Installs function blocks in the control strategy Select MAKE to display the SET MENU the processor s resident library of block categories detailed in the LIN Product Manual Part number HA 082 375 U999 Note that every strategy must contain a header block the only block initially available for a new strategy Select a category to list its blocks Figure 5 5 1 shows part of the screen display when LOGIC is selected as an example LOGIC Select type gt PULSE AND4 OR4 XOR4 Figure 5 5 1a Logic category menu upper part Select the block to be installed The block Overview appears listing the block parameters default values and units in a double 3 column format Figure 5 5 1b shows the default overview for the PID block as an example Note Blocks may not be configured if processor modules are synchronised Section 5 HA028225 Page 5 6 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 5 1 MAKE Cont BLOCK OVERVIEW Refer to Figure 5 5 1b below which shows the main features of a typical block overview used to monitor and update block parameters Overviews can also be accessed via the COPY and INSPECT main menu options The overview is equivalent to a LINtools Specification menu and its fi
78. Eurotherm utility for configuring networks of LIN instruments A proprietary communications protocol Gould Modicon Modbus RTU One or more processors running but not synchronised Programmable Logic Array In a Redundant mode system the primary is that processor which is in control The other processor is called the secondary processor The process supervisor consists of a backplane fitted with one or two Processor Modules and a connection module Processor Module should not be confused with Central Processor Unit CPU which is electronics hardware contained within the Processor module Characteristics of a process such as temperature pressure and valve aperture that can change value A communications standard Power supply unit Two synchronised processor modules the primary and secondary The secondary processor tracks the primary in every respect so that it can take command should the primary or the supply power to it fail RFI Radio frequency interference Secondary In a Redundant mode system the primary is that processor which is in control The other processor is called the secondary processor and it continuously tracks the primary so that it can assume control should the primary fail Synchronised During the start up sequence in redundant mode once the primary processor is running it copies database and function block data to the secondary Once this is complete and the database is running in both processor modu
79. JBUS RTU master Selectable between 600 and 38 400 Baud 8 bits 1 or 2 stop bits selectable parity Isolation 50Vdc 30V ac Profibus Connectors Parallel wired pairs of shielded RJ45 connectors per processor unit Protocol Profibus DP DPV1 Data rate Selectable between 9600 and 12M Baud Isolation 50Vdc 30V ac 1MQ to Chassis Other connections Supply voltage Safety Earth Battery backup Relay connections Two 2 way connectors per processor module for connection of 24V supply See backplane specification above For each processor unit one external battery can be connected using two terminals of an eightway relay connector block For each processor module there are one watchdog relay and two alarm relays operation configured by the user For each relay only the common and normally open contacts are used these being short circuit under normal operat ing conditions and open circuit under alarm or power off conditions Relay specification One watchdog and two user configurable relays per processor Contact rating resistive Isolation Contact to ground 30V ac 50V dc at 0 5 30V ac RMS or 50V dc 028255 Issue 3 04 Chapter 9 Page 9 3 PROCESS SUPERVISOR HANDBOOK 9 1 4 Processor Module specification General CPU type Flash memory Serial Communications Pentium MMX 266MHz gt 8 MByte Non isolated RS232 terminal configuration port RJ11 conn
80. L 9 03 9 04 9 05 9 06 9 07 9 33 9C34 9C35 9C36 9C37 9C38 9C65 9C66 9C67 9C68 9C69 9C6A Couldn t allocate the local storage that was required Error changing priority Need to supply an instance name Failed to get platform info Platform not known Feature not implemented QUE Insufficient memory supplied QUE Size of data for read or write invalid QUE Unable to write to queue Unable to read from queue Unable to allocate memory QUE No Kernel instance to make intra signal unique Signal already exists Failed to create signal Failed to open signal Failed to close signal Timeout waiting on signal A003 A004 A005 A006 A007 A008 A009 A00A AOOB Could not set user s event MAL Unable to grant system wide mutex due to it being in an inconsistent state Unable to grant system wide mutex due to a timeout Unable to grant system wide mutex reason un known Unable to grant system wide mutex as not created Unable to suspend user MAL Unable to allocate memory MAL Unable to change priority MAL Error waiting on signal MAL Table 6 6 2r Kernel items 9Cxx 9 01 9 02 9D03 9D04 9D05 9D06 9D07 Object already exists Out of objects Object does not exist Bad invocation parameter Object handle is now stale Object handle is invalid Too many users of object Table 6 6 25 Objects error codes 9Dxx 9 01 9 02 9 03 9 04 9 05 9 06 9
81. NCY MODES ie oe cae ete abe eit 4 1 4 2 START UP MODES 4 1 4 1 TEPID EE 4 2 42 2 Cold startz s 4 2 PARAMETER tee aet 4 2 AP 3 HOt COI SHOP titer tease its adhi ette ie Mont 4 3 Test PR ER C dde 4 3 4 3 STARTING SINGLE NON REDUNDANT PROCESSOR 4 5 4 3 1 Startup Sequence 4 5 OFF STATE si eR testet 4 5 STARTING STATE 2 OY er e E 4 5 PRIMARY UNSYNCH 4 6 4 3 2 Watchdog indications sess 4 6 43 9 Watchdog relay Peta ie deeb ended Ped eene Set 4 6 4 4 STARTING UP A PAIR OF 4 7 4 41 Redundant mode etc eh ons s mter e Ee cod 4 7 PRIMARY SECONDARY CRITERIA 22 2 2 2 4 7 4 8 2256 teet et rhet 4 8 TIME TO SYNCHRONISE ree aa 4 8 4 4 2 Non redundant mode 22 4 8 4 5
82. OMBIC104 PB Version V01 058 29 05 01 Ethernet MAC address 00 E0 4B 00 45 DA IP address 149 121 165 188 Subnet mask 255 255 252 0 Default gateway 149 121 164 253 POST result 0000 SUCCESS Hotstart failed because Warmstart switch is disabled Last shutdown because Successful Power Down 1 ANSI CRT gt gt gt Figure 5 4 1a Typical sign on screen Ethernet MAC address Shows the address of the ethernet interface This value is unique and is permanently fixed for an individual instrument IP address Gives the IP address currently assigned to this instrument This address must be entered manually Subnet Mask Gives the subnet mask currently assigned to this instrument An IP host uses the subnet mask in conjunction with its own IP address to determine if a remote IP address is on the same subnet in which case it can talk directly to it or a different subnet in which case it must talk to it via the Default Gateway Please see IP Subnets below Default Gateway Gives the IP address of the Default Gateway It is the address via which this instrument must talk in order to communicate with IP addresses on other subnets If undefined 0 0 0 0 then this instrument can only talk to other IP hosts on this same subnet Hyperterminal is a trademark of Hilgraeve Inc HA028225 Section 5 Issue 3 Jly 04 Page 5 3 PROCESS SUPERVISO R HAN DBOOK 5 4 1 INITIAL MENU ACCESS Cont If Modbus
83. R Byte 1 ALIN address gt gt gt ffffff60 166 Byte 2 ADDR HIGH register gt gt gt 88 136 Byte 2 bit7 Power Fail gt gt gt il Byte 2 bit6 RTC Battery Failure gt gt gt 0 Byte 2 bit5 Over temperatur gt gt gt 0 Byte 2 bit4 CPU fan stall gt gt gt 0 Byte 2 bit3 Main Batt failure gt gt gt 1 Byte 2 bit2 Main fan stall gt gt gt 0 Byte 2 bitl Backplane SW2 2 gt gt gt 0 Byte 2 bit0O Loom detect gt gt gt 0 Byte 3 DIL register gt gt gt 8c 140 Byte 3 bit7 Backplane SW2 6 SRD gt gt gt 1 Byte 3 bit6 mode 4 Hot gt Cold gt gt gt 0 Byte 3 bit5 Hardware Build Lev 1 gt gt gt 0 Byte 3 bit4 Hardware Build Lev 0 gt gt gt 0 Byte 3 bit3 Backplane SW2 5 MDB gt gt gt 1 Byte 3 bit2 Halt gt gt gt 1 Byte 3 bitl mode 2 Hot gt gt gt 0 Byte 3 1 0 mode Cold gt gt gt 0 Byte 4 OPT register gt gt gt FF 255 Byte 4 bit7 Hardware Build Lev 4 gt gt gt Byte 4 bit6 Hardware Build Lev 3 gt gt gt Note Byte 4 bit5 Hardware Build Lev 2 gt gt gt OPT register is not displayed for Byte 4 bit4 Power Fail interrupt gt gt gt units with hardware build levels 0 or Byte 4 bit3 Backplane SW2 8 gt gt gt 1 In such cases Bytes 4 and 5 are Byte 4 bit2 Backplane SW2 7 gt gt gt ILOCK_RDO and ILOCK RDI reg Byte 4 bitl Backplane SW2 4 gt gt gt isters respectively Byte 4 bit0O Backplane SW2 3 gt
84. R b 3 3 33 ALARM LEDS oi P 3 4 3 4 COMMS TEDS ee pneter e eere ee ete e E dil 3 5 3 4 1 System A B ional akin tears eese 3 5 3 4 2 Expl Dessin cii e ERR EO e ER ER tbt 3 5 3 4 9 Exp 2 DU Des deo Poet 3 5 3 5 CHANGEOVER LEDS AND SWITCHES 3 6 35 1 Primary LED coo pr gr Duties ie ous 3 6 3 52 Standby LED t RUE Ress 3 6 3 5 3 Sync changeover switch sss eme 3 6 3 5 4 Desynic eee 3 6 3 5 5 Processor module Synchronisation 3 7 TIME TO SYNCHRON USE hs E ees 3 7 3 6 STARTUP IEDS AND SWITCHES 3 8 3 6 T LED D te eee net es 3 8 3 6 2 Duplex nni rte ee tr eerte re ee be it 3 8 3 6 3 Restatt switch erste DEG E EE A 3 8 3 6 4 EP DU He 3 9 3 6 5 Startup modes ice epa UD Glee UN eiie 3 9 eM M E ER RT M 3 9 cians 3 9 HOT GOLD 4 55 3 9 TEST ties eoe wee elidel cade ea eases 3 9 Cont 028225 Section i Issue 3 04 Page i PROCESS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page CHAPTER 4 nnna 4 1 REDUNDA
85. ROCESS SUPERVISO R HAN DBOOK 5 5 6 UTILITIES Allows program control I O calibration and filing Select UTILITIES from the main menu to display the Utilities options shown in Figure 5 5 6 UTILITIES Select option gt START Start runtime system STOP Stop runtime system SAVE Save database LOAD Load database FILE File page APPLY Apply Changes UNDO Undo Changes ELIN Elin Setup Figure 5 5 6 UTILITIES options menu START STOP UTILITIES Select START or STOP from the UTILITIES options menu and press Enter to start or stop the control program running in the processor Note When you START a database in RAM it is automatically saved to the file in E drive called filename DBF where filename is indicated in the filename RUN file It is then reloaded and started SAVE UTILITY Names and saves a control program to a specified memory area Select SAVE from the UTILITIES options menu the default filename specification E T940 DBF is displayed The prefix E directs the save to the local E drive area of the processor this is the only available memory area To save a database to a remote instrument prefix the filename specification by the node address of the instrument separated by a double colon e g FC E T940 DBF Type in a new specification if needed then press Enter to execute the save After a short pause the processor mod ule signals completion with the message Type a
86. Sequence edundant mode working Fled ndantm de 4 7 With config 2 412 1 4 10 With server stall 4 11 HA028225 Index Issue 3 Jly 04 Page 3 PROCESS SUPERVISOR HAN DBOOK S Cont U Starting slate oe es ee 4 5 v ie De ede eres 5 1 5 15 STOP ettet aide ctio 5 1 5 14 Uripacking semper 2 2 Stop bits cnm pte bed 5 3 5 17 Update period 5 8 Subnet 5 3 5 16 User SUpply fUSes x nece gei 2 15 3 3 Defined 5 8 Supply Wiring eicere ree cote nenne 2 15 a 7 3 SW1 SW2 locations 2 24 2 5 server operation 7 4 eh dome Aii ettet at deese 2 7 CUMING 7 5 Switch Utilities 5 1 5 21 Rd Lee cu 3 6 Bale hen niu un CE E 3 8 V da ee os tenes 3 8 M SVING cioe atem ames 3 6 VDU package Ea Ra 257 Switches W Location of 2 5 Sync ettet Site er 3 6 Wall mounted enclosure 2 3 Synchronisation ete ee 3 7 4 84 12 Watchdog 4 6 Time to achieve usce coe vate 3 7 4 8
87. Should the CPU fail to initialise fully the final pattern of these LEDs may be of use to service engineers but is not interpretable by the user Note This CPU is a part of the internal electronics of the Processor Module and the two terms should not be confused K Process C suite Processor Power Alarms 4 Comms 10 20 V 40 O80 2 primary O standby 02 01 E f N config 22 a An Invensys company ES J Figure 6 4 BIOS LEDs and their code values Chapter 6 Page 6 10 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 4 POWER ON SELF TESTS Cont Once the CPU is running it runs the Boot ROM Flash disk which enables the system monitor SMON If the sys tem monitor is not entered within one second the start up process continues with the loading of the application and system code from the FLASH ROM accessible at the rear of the unit At this point a 1 second entry point for a second monitor the M monitor appears 10 seconds for TEST start up Refer to Section 8 4 for details of the monitors The POST now checks that all the electronic systems hardware is available for the Communications protocols re quired by the software If not this is deemed to be Serious Hardware Fault and although the power up sequence continues the processor will not load a data base and will stop wi
88. a Eurotherm Recorders Inc 741 F Miller Drive Leesburg VA 20175 8993 Telephone 1 703 669 1342 Fax 1 703 669 1307 e mail Sales sales chessell com e mail Technical support chessell com http www chessell com Invensys EUROTHERM EUROTHERM LIMITED Faraday Close Durrington Worthing West Sussex BN13 3PL Telephone 01903 695888 Facsimile 01903 695666 e mail info eurotherm co uk Website http www eurotherm co uk Specification subject to change without notice Eurotherm Limited HA028225 3 20490
89. ady been described in section 7 1 2 above The user task servers are set to run no more than once every task repeat time as specified by the corresponding TaskRptn parameter Figure 7 2 2a shows schematically how the servers interact with each other according to their priorities The darker bars represent running tasks and the paler bars represent suspended tasks running Task suspended User task 1 repeat time User task MEM SS User task 2 User task 3 m User task 4 Cached sync server E n EJ Priority Cached conn server n E Time Figure 7 2 2a User task server interactions HA028225 Chapter 7 Issue 2 Nov 03 Page 7 3 PROCESS SUPERVISOR HANDBOOK 7 2 2 USER TASK SERVERS Cont USER TASK SERVER OPERATION A higher priority user task server always interrupts the running of a lower priority user task server Thus whenever a given user task is running all higher priority user tasks must have run to completion Figure 7 2 2b shows schematically the sequence of events that occurs during the running of a user task server These are as follows 1 The user task is marked as busy During this busy period lower priority tasks are suspended 2 connections sourced from higher priority tasks are copied into their destination blocks in this user task This Occurs as a single indivisible operation 3 The blocks and their associated intra ta
90. aluation 2 Connections writing to cached block These are connections whose destination block is a cached copy of a block in another instrument The source of the connection can be either a local database block or another cached block Such connections are evaluated only if the source and destination data do not match All cached blocks in the database are processed at regular inter vals and whenever a change is detected a single field write is performed over the communications link HA028225 Section 5 Issue 3 Jly 04 5 11 PROCESS SUPERVISO R HAN DBOOK 5 5 1 CONNECTION TYPES IN A PROCESSOR MODULE DATABASE Cont 3 Connections from cached block to local block These are connections where the source block is a cached copy of a block in another instrument and the destina tion block is local to the processor module database All cached blocks in the database are tested at regular inter vals and if a change in the block data is detected then all such connections out of the cached block into local blocks are evaluated The connections are not evaluated if the source data has not changed This third type of connection is unique to redundant processor systems duplex processors Such connections are evaluated in this way to minimise the load involved in synchronising the databases of a duplex pair whilst ensuring the coherence of the data between the primary and secondary processor units Caution With this third type of connec
91. and slide the lower panel containing the battery board out until the board fixings become accessible 3 Disconnect the battery connector 4 Retaining all fixings undo the two M3 screws securing the board to the case 5 Remove the battery board and place it in a safe non conductive area Dispose of the battery board according to local regulations regarding Nickel Metal hydride batteries 6 Fitthe new board using the fixings previously removed 7 Re assemble the unit following section 8 2 1 steps 9 to 12 Section 8 HA028225 Page 8 4 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 2 5 Flash card Replacment Figure 8 2 5 shows the replacement of the Flash card fitted to current units This procedure allows data bases user configurations etc to be transferred from one processor module to another allowing the Mean Time to Replace to be reduced to a minimum 1 At the rear of the instrument lift the front edge of the card and pull it out of its connector 2 Fit the replacement card Figure 8 2 5 Flash card removal 8 2 6 Firmware upgrade The manufacturer can supply replacement memory flash cards pre programmed with the latest firmware version This allows the user to upgrade the unit just by replacing the card In such cases the user is responsible for reloading con figuration files in the unit Alternatively the manufacturer s agents can upgrade the firmware version with the card in situ thus retaining the
92. anges in the plant being controlled Initial configuration to Cus tomer Specification is normally carried out prior to delivery Diagnostics how to diagnose faults that could develop in the instrument by recognising fault indica tions Task Organisation and tuning Service Technical Specification and order codes The contents of any other manuals in this binder are listed within those manuals OTHER INFORMATION SOURCES For details of LIN based function blocks their parameters and input output connections refer to the LIN blocks ref erence section of the LIN product manual HA082375U999 which explains how control strategy LIN blocks selected interconnected etc The creation and monitoring of databases and communications configurations is de scribed in the Eurotherm Project studio documentation The configuration of Sequential Function Charts SFCs is described in the T500 550 LINtools User Guide HA082377U005 Modbus and Profibus implementations are dis cussed in the Communications Manual HA028014 1 3 THE PROCESS SUPERVISOR UNITS 7 ee 2 EUROTH Process EUROTHI Process I 8 EUROTH suite suite suite Connect Processor Processor Power Alarms er Alarms al
93. ansient and clear within approximately two seconds 2 In redundant operating mode the secondary refuses any ALIN messages other than identity requests All database related comms and file system comms are handled by the primary processor TIME TO SYNCHRONISE The time taken to complete the synchronisation process varies according to the complexity of the control strategy and on how heavily the Flash file system is used Typically the Load and Run part of the procedure takes a number of seconds and the file transfer can take some minutes Where primary and secondary databases have substantial differences e g when attempting synchronisation for the first time multiple syncs may be required to copy all the files to the secondary When such is the case it can be de tected from the Red Ctrl block sync fields 4 4 2 Non redundant mode Starting a pair of processors in non redundant simplex mode is the same as starting a single processor Whether the units power up in redundant or non redundant mode depends on the setting of the SRD element of the Options switch SW2 on the back plane see Section 2 4 in Chapter 2 of this manual Chapter 4 HA028225 Page 4 8 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 4 5 LED FAULT INDICATIONS The Alarm Comms and Primary and Standby LEDs are illuminated in various patterns during the first part of the start up sequence Should the sequence stop at this time the pattern of these LEDs give
94. ause it is assembled only from com pleted tasks Also contained in the tepid data package are a number of explicitly defined fields specified in a TPF file The maxi mum total number of fields including the SL OP and MODE fields is 2560 The TPF file consists of a list of param eters for example PIC 023 Mode XCV 124 Mode Profile A0 If the tepid data file exceeds 10 the power hold up may not be long enough to ensure all the data gets stored 4 2 2 Cold start Cold start means that the instrument re starts with the previous database loaded but with all parameters and values set to starting values appropriate to the process that is re initialised If the cold start fails the data base will be cleared and the processors enter an Idle state and remain there until physically restarted PARAMETER FILE In the event of a cold start the instrument searches for a file with the same name as the DBF file just loaded but with the extension CPF If such a file is found it is executed The CPF file created using any text editor consists of Structured Text ST style assignment statements one complete statement per line of text that allocate cold start pa rameter values to database block fields Fields that are normally read only can be written to from the cpf file by adding the gt character to the beginning of the assiggnment statement A CPF file can also include ST comment lines e g Comment The instru
95. cessors are powered up within 1 second of one another AND they were running as a synchronised pair prior to power down data held in battery backed memory then synchronisation will take place without operator interven tion If either of the above conditions is not met or if the battery backed data is not available then both units will enter unsynchronised states in which case the secondary cannot take over from the primary This state will continue until the sync switch on the primary processor is operated SYNCHRONISATION During synchronisation automatic or manual the primary processor carries out the following 1 The transfer of any cold or hot start data base files to the secondary 2 Itinstructs the secondary to load the relevant database 3 Once this is complete transfers current block data to the secondary During the synchronisation process the Standby LED on the secondary processor front panel flashes Once syn chronisation is complete the Standby LED is continuously illuminated yellow the Duplex LED is illuminated green and redundant operation starts with the processors in their synchronised states In these states the secondary con tinuously tracks the primary by receiving data from it including attachments input reads block execute synchronisa tion commands check sums block data and health data Notes 1 During synchronisation some peripherals may report comms failure Such failures are tr
96. ch to run between higher priority tasks Section 5 HA028225 Page 5 2 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 4 RUNNING THE CONFIGURATOR This section describes accessing and quitting the Configurator using HyperTerminal If a different terminal program is being used its user documentation should be consulted if necessary for the equivalent procedures Which screen appears at start up depends on whether the Instrument is running before HyperTerminal or as de scribed below it is switched on after HyperTerminal In the former case the sign on screen described below does not appear neither does the 1 51 message To get to the initial menu type lt 1 gt one and wait for the menu to be displayed Note The sign on screen also appears when quitting the terminal configurator 5 4 1 Initial menu access 1 Power up the PC and start Hyperterminal Programs Accessories Hyperter minal After entering a name for the link if necessary enter the Properties menu and select VT100 In Properties Connect to Configure Connection set the comms parameters as follows Baud rate 9600 Data bits 7 Stop bits 1 Parity Even 2 When the hyperterminal starts power up the instrument The sign on screen appears Figure 5 4 1a below shows a typical display 3 Type lt 1 gt to display the initial menu Process Supervisor 4 1 at 266 MHz Hardware Build 00001 Profibus card PB C
97. ckage that was running when the error oc curred and the last two specify the particular error associated with that package RUNNING PACKAGES Packages are defined as 82 File system table 6 6 2a 83 Database system table 6 6 2b 85 Objects system table 6 6 2c 86 Trend system table 6 6 2d 87 Control config table 6 6 2e 89 Network error table 6 6 2f 8B Sequence database system table 6 6 2g 8C Sequence runtime system table 6 6 2h 8D Structured text system table 6 6 21 8F PCLIN PC I F package table 6 6 21 90 T1000 menu system table 6 6 2k 9 Configuration files table 6 6 21 6 6 2 Error messages 99 9A 9B 9C 9D 9E AO Al A4 6 AD External database table 6 6 2m MODBUS codes table 6 6 2n Xec codes table 6 6 2p Kernel items table 6 6 2r Objects table 6 6 2s Locks table 6 6 2t Machine Architecture Library MAL table 6 6 2u Application Master Comms AMC table 6 6 2v Modbus Master Comms MMC table 6 6 2w Asynchronous I O table 6 6 2x Profibus table 6 6 2y Table 6 6 2 lists error messages package by package Note that this is a complete list of all error messages generated by LIN based systems and therefore includes errors that are additional to those which can be generated by the Proc ess Supervisor The error code FFFF means unknown HAO28225 Issue 2 Nov 03 Chapter 6 Page 6 13 PROCESS SUPERVISOR HANDBOOK 6 6 2 ERROR MESSAGES Cont Not
98. d if the unit s operation is impaired but still capable of running These errors are 1 ELIN ALIN Profibus hardware failure Results in an inability to communicate with those systems using the par ticular protocol The relevant front panel LEDs are continuously red 2 Less than 8 MB of memory in dynamic RAM 3 No config txt file normally installed on the system FLASH device or created via the monitor FATAL ERRORS 6 5 A fatal error is one where the unit s operation is impaired to the extent that it cannot continue to operate or cannot start up In a redundant system the processor modules will desynchronise This type of error is caused when Flash memory is not available due to a hardware fault DIAGNOSTIC BLOCKS Several diagnostic function blocks are available from the DIAG category that can be installed in the control database at configuration time to help in diagnosing any error conditions that may arise in the running strategy The VIEW facility in the LINtools package can then be used via the LIN network to look at the fields in these blocks to find out what is happening Alternatively a terminal emulation program running in a PC can be used to access the processor module s resident configurator via the EIA232 CONFIG connector to allow the diagnostic block parameters to be viewed in inspection mode These diagnostic blocks are described in the LIN Product Manual part number HA082375U999 The table below provides a brief s
99. diagnostic information as follows POWER LEDs If either of the Power LEDs fails to light green on power up there is a fault in the relevant power supply or the Con nect module has been removed If the Connect module is correctly fitted isolate the power supply unit and remedy the fault WATCHDOG LED If the Watchdog LED changes from short green long red to steady red the hardware has failed the temperature and fan tests Switch off and remedy the fault If the Watchdog LED changes from long green short red to steady red one or more components of the software have not loaded properly Switch off switch on and if still unsuccessful contact a service engineer If the Watchdog LED changes from steady green to red an operational fault has developed PRIMARY LED If this LED is off power to the processor module is off or the processor module is not the primary If the LED is flashing green off there is no database running either because the unit is still starting up or because a database has not been loaded or has failed to start COMMS LEDs The comms protocol e g Modbus ALIN etc associated with any one comms connector is configurable and it is therefore not possible to be more specific about failure indication than the following SYSTEM AND I O LEDS If a system or I O comms LED does not light green the processor module has not yet established communications If the LED is illuminated continuously red there is a hardware
100. e 7 1 3 Task Functions A complete list of task functions is given in table 7 1 3 below The following paragraphs give explanatory details NETWORK TASK This task is repeat driven every 15 msec approx The task performs housekeeping for all transactions transmitted or received over LIN NFS TASK This event driven Network Filing System task processes LIN filing system requests Filing system requests get a much larger share of CPU time when the database is halted This is due to the low position of the NFS task in the prior ity structure USER TASKS 1 TO 4 These tasks are responsible for running up to four user tasks The tasks are repeat driven at the TaskRpt rate set in the instrument header block subject to the requested repeat rates not exceeding the maximum permitted CPU loading User task 1 has the highest priority followed in descending order by user task 2 user task 3 and user task 4 lowest priority CACHE SYNC SERVER This task is used to maintain synchronisation of cached blocks The task is repeat driven every 100 msec but this may be extended depending on the available CPU time available after servicing User Tasks CACHE CONN SERVER This task is responsible for processing LIN network field writes into and out of cached blocks The task is repeat driven every 100 msec but this may be extended depending on the available CPU time available after servicing User Tasks HA028225 Chapter 7 Issue 2 Nov 03 Page 7
101. e To synchronise the processors the primary s sync push switch must be operated Once synchronisation has been achieved the processors are said to be in primary synch state and secondary synch state and the secondary is able to take over from the primary if required Note With some peripherals comms failures may be reported during the synchronising process TIME TO SYNCHRONISE The time taken to complete the synchronisation process varies according to the complexity of the control strategy and on how heavily the Flash file system is used Typically the Load and Run part of the procedure takes a number of seconds and the file transfer can take some minutes During this period the primary processor runs the control proc ess as normal 028225 Chapter 3 Issue 2 Nov Page 3 7 PROCESS SUPERVISOR HANDBOOK 3 6 STARTUP LEDS AND SWITCHES The Restart and halt switches are set behind the panel and should be operated when necessary by a blunt plastic tool such as the recessed end of a trim pot adjuster Restart O wdog config hot hot cold cold EO tes halt O duplex Figure 3 6 Startup control and monitoring This group of components is located near the bottom of the processor module front panel and consists of two LEDs two push switches and a four position rotary switch 3 6 1 wdog LED This LED gives information about how start up is progressing
102. e Cold Start time is a pre set duration following power off after which a Hot Start is not possible and a Cold Start must be initiated instead The process of specifying the components of an application A control strategy is the overall programmed function of the LIN database within an instru ment ready to act upon a real life process Classless Inter domain Routing A standard for IP addressing Control of Substances Hazardous to Health legislation Cold Start Primary the left hand processor module Applies to redundant mode systems only Cold Start Secondary the right hand processor module Applies to redundant mode systems only Dynamic Random Access Mamory Twin synchronised processors capable of operating in redundant mode External database Electrically Erasable Programmable Read Only Memory Local Instrument Network LIN protocol on Ethernet Electro magnetic compliance A suite of programs for building testing and configuring programs and systems for process control and I O A control monitoring configuration system for use with process supervisor units Function block Function Block Diagram a programming language A unit of software that performs a named function It can be linked to other function blocks to build a LIN database and hence a control strategy for an instrument A GSD Geratestammdaten file contains instrument parameter information which a Profibus master needs in order to communicate with the instrume
103. e connection These types and the way in which data coherence is ensured are as follows CONNECTIONS INTO TASKS FROM OTHER TASKS IN THE SAME INSTRUMENT NODE In order to ensure that multiple uses in this task of the same value from another task always use the same iteration of the value such values are copied prior to the execution of all the executable blocks of this task i e a snapshot is taken of all values external to this task Two types of connection apply those from higher priority tasks to lower priority tasks and those from lower priority tasks to higher priority tasks 1 Higher to lower priority For coherence whenever connections out of a task are used all their values must result from the same iteration of that task Owing to the priority structuring of the tasks any connections from a higher priority task into a lower priority task meet this requirement This is because a lower priority task cannot interrupt a higher priority task which therefore always runs to completion Hence these connections are dealt with by a snapshot copying at the start of the lower priority task 2 Lower to higher priority A low priority task may be interrupted by a higher priority task before completion and so be caught with an incoherent set of output values To avoid such invalid values being passed on the last action of task execution is for the lower priority task to copy its set of coherent connections as a
104. e g Unackd status e g Active and priority 0 to 15 Update the acknowledgement or priority fields the only editable ones by typing in a value and pressing lt Enter gt Any single letter can be used for the acknowledge ment field Figure 5 5 1f shows an example Alarms page Alarms Software HighAbs LowAbs HighDev LowDev Combined Block Unackd Unackd Unackd PID_1 Active Active Active Active Figure 5 5 11 Alarms page example Section 5 Page 5 10 HA028225 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 5 1 MAKE Cont 6 Bitfields Contain eight or sixteen binary digits showing the logic states of a corresponding set of up to eight or sixteen parameters To edit the bitfield directly type in a bit pattern then Enter it Alternatively press Enter to display a Full Description page listing the parameter TRUE FALSE or HIGH LOW states in the same format used for LINtools Specification Menu bitfields Figure 5 5 1g shows an example Alter a logic state by locating the cursor on the state typing in T rue or F alse and pressing Enter A bit may be read only L FULL DESCRIPTION Field ModeAct Block PID 1 Type PID NotRem TRUE HoldAct FALSE TrackAct FALSE RemAct FALSE AutoAct TRUE ManAct FALSE FAutoAct FALSE FManAct FALSE Figure 5 5 19 FULLDESCRIPTION page for bitfield example To connect an input to a bitfield
105. e may exceed 40V peak with respect to Safety Earth potential 2 Should the supply voltage fall below 18 Volts during startup caused for example by current limiting on the Power supply unit the processor will fail to start successfully It will then attempt to restart and enter a repeating cycle Damage will occur to the unit if this cycle is allowed to continue FUSES AII positive supply lines must incorporate a fuse Suitable types are 3A Type T for 24 Volt supplies and 0 5V Type T for each external battery fitted 42 d ril rl2 batt ril 2 batt 7 DT OR left processor right processor Recommended wire sizes DC supply single wire 0 2mm to 2 5mm 20 awg to 14 awg Relays battery single wire 0 14mm to 1 5mm 25 awg to 16 awg Fuse types fuses to be fitted in positive supply line 24V supply T External battery 0 5A Type T Figure 2 5 1g DC and relay connection details HA028225 Chapter 2 Issue 2 Nov 03 Page 2 15 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont Relay Power off state RELAY WIRING There are three relays associated with each processor module and the common and normally open terminals of these relays are wired to the front of the Connect module as shown in figures 2 5 1h and 2 5 11 The contact ratings resistive loads for the relays are 30V 50 at 0 5A The operational strategy o
106. e nearest manufacturer s agent for repair 2 2 UNPACKING The instrument and accessories should be carefully unpacked and inspected for damage The original packing materi als should be retained in case re shipment is required If there is evidence of shipping damage the supplier or the carrier should be notified within 72 hours and the packaging retained for inspection by the manufacturer s and or carrier s representative Chapter 2 HA028255 Page 2 2 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 2 1 Handling precautions Caution Circuit boards inside the units contain components which can be damaged by static electrical discharge Before any circuit board is removed or handled it should be ensured that the handler the instrument and the circuit board are all at the same potential 2 2 2 Package contents Note The process supervisor may form part of a larger assembly and or may be housed in a floor or wall mounted enclosure If so the documentation that accompanied those items should be referred to The package contents should be checked against the order codes using the labels on the components Order codes are listed in Chapter 9 of this handbook PRODUCT LABELLING 2 3 Product labelling includes 1 Sleeve label On the outside of the processor and connect module sleeves showing the model number serial number and hardware build level 2 Backplanelabel On the edge of the backplane showing the model
107. e status of the various communications systems associated with the Process Supervisor Table 3 4 1 below explains the interpretation of these LEDs together with individual error weights which are used in redundant systems to determine what action to take in case of error see section 4 8 LED Description Steady Communications running successfully green The unit is running Profibus and successfully Flashing green communicating with at least one slave but i oB only other slaves not responding This fault cannot appear on a Redundant Secondary as the necessary information is not available to it Flashing The unit is running but it cannot communicate Faulty red e g because of a cable break network Faulty hardware ad Process Supervisor hardware fault re Off The relevant comms system is not running Not running System A ELIN System B ELIN I OA ALIN Profibus Table 3 4 1 System and i o LED interpretations and error weights 3 4 2 Expl tx rx This pair of LEDs indicates communications activity at the exp1 expansion 1 port of the Connect module When working correctly the LEDs flicker yellow at varying rates according to processor receive rx and transmit tx activ ity 3 4 3 Exp2 tx rx This pair of LEDs indicates communications activity at the 2 expansion 2 port of the Connect module When working correctly the LEDs flicker
108. ector Panel Indicators Light emitting diodes LEDs for Main supply 24V nom External battery optional Internal battery optional Alarm relay status Serial communications ALIN Profibus status Primary processor Standby processor Watchdog indicator Duplex redundant mode indicator Control switches Push button switches for Rotary switch for Watchdog Halt Watchdog Restart Processor module synchronisation changeover Processor module desynchronisation Startup mode selection Section 9 Page 9 4 028255 Issue 3 04 PROCESS SUPERVISOR HANDBOOK 9 1 5 Software specification LIN Block libraries continuous database function block categories 1 0 Conditioning Control Timing Selector Logic maths Config Diag Batch Analogue and digital input output manual override Dynamic signal processing and alarm collection Analogue control simulation and communications Timing sequencing totalisation and events Selection switching alarm and display page management Boolean latching counting and comparison Mathematical functions and free format expressions Unit identity blocks Diagnostics Sequencing recipe record and discrepancy checking Continuous database resources Number of function blocks maximum Number of templates maximum Number of libraries maximum Number of EDBs maximum Number of FEATTs maximum Number of TEATTs maximum Number of
109. elds have the same meanings although data entry is different Note that parameters being updated by incoming connections from other blocks are not specially indicated in a block overview EW Block NoName Alarms FallBack HAA 100 PV LAA SP 100 LDA 100 SL TrimSP 1 TimeBase Secs RemoteSP E XP 100 0 Track TI 0 000 TD 0 000 HR SE LR SE Options 00001100 HL SE 0 SelMode 00000000 LL_SE ModeSel 00000000 HR_OF ModeAct 00000000 LR_OF HL LL_OE C o o9 oe oe FF PID 50 0 FB OP 0 0 C Figure 5 5 10 Overview PID block TITLE BAR Contains fields common to all overviews Block Type and DBase Details of these fields are to be found in the LIN Blocks Reference Manual in the LIN Product Manual A blank DBase field denotes that the block database is local Note The block is not installed into the control strategy until at the minimum its Block field has been assigned a value i e tagname and either the database has been restarted or APPLY operated in the Utilites menu OVERVIEW DATA FIELD ENTRY To update a parameter field locate the flashing underline cursor _ at the field using the arrow keys then proceed as described next for the different data field types Some data fields display further nested levels of data when entered as detailed in the following sections Press Enter to access
110. er Select Protect to write protect the Modbus register bit s or Enable to allow overwriting Notes 1 The easiest way to protect an entire table in a gateway operating in master mode is to disable its write function codes 5 and 15 or 6 and 16 in the tables list 2 32 bit register pair MOD Write applies only to the first register The MOD Write value of the second register is ignored This column shows the current 16 bit value of the field in 4 digit hexadecimal representation Value is read only 5 6 4 Utilities The Utilities menu allows Modbus configurations to be saved and loaded Files may be copied to and retrieved from the local processor module or from a remote instrument across the LIN The Modbus configuration is stored in a file with extension GWF and the root filename should be the same as that of the corresponding database DBF file Select UTILITIES in the Gateway menu to see the options shown in Figure 5 6 4 UTILITIES File Load amp Save gt SAVE MODBUS Configuration LOAD MODBUS Configuration Figure 5 6 4 UTILITIES menu SAVE Select SAVE and press Enter to see the default filename specification E T940 GWF To save the current Modbus configuration under the default filename press Enter again To save it under a different filename edit the file name before carrying out the save operation Note An existing file with the same
111. er to the ordering guide in Chapter 10 4 Supply power range is 7 to 35Vdc Worst case PORT 1 inrush current 660mA at 4V 8 way Figure 2 5 2a Isolator wiring details HA028225 Chapter 2 Issue 2 Nov 03 Page 2 17 PROCESS SUPERVISOR HANDBOOK 2 5 2 PROCESSOR MODULE Cont omm i N C N C 2 mme 2 Rx ov 3 Tx 1 1 emmm4 Se 5 5 10 Om emm DSR L _ J 7 RTS 6 Way RJ11 Male l to Processor module CTS emmmO9 N C bd 9 Way D type socket To PC 5232 REAR VIEW NC imme om NC 1 2 2 11x ovi 3 Tx 4mm 1 omm 4 l 5 5 Ce Omm 6 L J 7 lov 6 Way RJ11 Male to Processor module l 25 Way D type socket To PC RS232 port REAR VIEW Figure 2 5 2b Direct connection between CONFIG port and PC Chapter 2 HA028255 Page 2 18 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 5 2 PROCESSOR MODULE Cont CONFIGURATION OF CONTROL STRATEGIES AND SEQUENCES You can configure control strategies and sequences for the Process Supervisor using either an external PC based graphical software package Eurotherm Project Studio or with the simpler i
112. ernal battery can be fitted to maintain the RTC for a minimum of 72 hours Chapter 8 gives installation replacement procedures for the internal battery and Chapter 9 gives details of suitable batteries both internal and external HAO28225 Chapter 2 Issue 2 Nov 03 Page 2 3 PROCESS SUPERVISOR HANDBOOK 2 3 1 Layout drawings 150 1 06 5 Process supervisor Process supervisor eig D C Earth st Per Teu 4 4 p an 4 4 oe wo 382 lt gt 402 Figure 2 3 1a Dimensions mm Process Supervisor IUROTHERM Processor suite Alarms nm enm ep primary standby sync changeover desync Restart Q wdog cold 1 cold FO EO halt duplex An Invensys company J Figure 2 3 1b Processor module front panel layout Tolerance 0 5mm except where shown otherwise Connect Process Supervisor EUROTHERM fO C suite 1 system 1 1 1 Hl H2 wdog batt LL tn ab ab ab ab TEL TTT To
113. ese can be displayed on a VDU terminal attached to the front panel EIA232 CONFIG connector see chapter 2 These messages appear when configuration mode is accessed Full lists of error messages are given in section 6 6 of this chapter Figure 6 3 1a charts the power up routine in a simplified schematic form and figure 6 3 1b shows the hot start sub routine that may be called by the main power up routine The two flow diagrams also show various error conditions 028225 Chapter 6 Issue 2 Nov Page 6 7 PROCESS SUPERVISOR HANDBOOK 6 3 1 PROCESSOR UNIT POWER UP ROUTINE Cont unit secondary unsynch Y Unsynchronised secondary No database running last time N Hot start disabled shutdown ast time Extract last known status from memory Does Database fast loaded dat E base match Flash filing system Run file mismatch Y Switch set to cold or 2 Run hot hot cold Isable start routine fig 6 3 1b Try to get DBF file as hot start N that matches RUN successful file in Flash Was N cold start set to Hot successful Y Y Run data base Run data base Hot start Cold start Create empty database Figure 6 3 1a Processor unit power up routine flowchart simplified Chapter 6 Page 6 8 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 3 1 PROCESSOR UNIT POWER UP ROUTINE Cont Hot start called
114. ess Supervisor A cyrotnerm Processor oy suite POWER ALARMS 24V battery nm COMMS system expl Ix rx i o exp2 PRIMARY O STANDBY sync O changeover desync O RESTART CONFIG E halt duplex Figure 4 3 1 Processor module front panel OFF STATE In the Off state all LEDs are extinguished STARTING STATE When power is applied the relevant Power LED s illuminate green immediately The Basic I O System diagnostic LEDs rl2 expl rx expl tx exp2 rx exp2 tx Primary and Standby flash inter mittently until the processor is initialised at which point they all switch off See chapter 6 for more details of these LEDs Wdog flashes green red until the sequence is complete and the CPU has started running the applications software after which it is illuminated continuously green See section 4 3 2 below for further details The start up procedure concludes with the processor attempting to establish Ethernet ELIN or Arcnet ALIN com munications depending on whether an ARCNET card is fitted and whether ELIN On in the network unh file During this period the Primary LED flashes on and off HAO28225 Chapter 4 Issue 2 Nov 03 Page 4 5 PROCESS SUPERVISOR HANDBOOK 4 3 1 START UP SEQUENCE Cont PRIMARY UNSYNCH STATE When the start up sequence is co
115. essor CONFIG port see section 2 5 2 below RJ 45 plug View on underside EIA422 485 EIA485 EIA422 485 5 wire 3 wire 5 wire TxB EIA485B RxB TxA EIA485A RxA Signal common Signal common Signal common Not used Not used Not used Not used Not used Not used Signal common Signal common Signal common c BY N c NI BY N CO BY N RxB Not used TXB RxA Not used Plug shroud to cable Plug shroud to cable Plug shroud to cable screen screen screen Slave device Master slave device Master device exp1 2 exp1 2 exp1 2 EIA485 B EIA485 A Signal common TX Rx Not used Not used Not used ALIN A ALIN B Not used Not used Not used Not used Rx Not used Not used 5V for pull up Not used Not used olni om om wo pl a 1 2 3 4 5 6 7 8 Not used NI A N Not used Not used Plug shroud to cable Plug shroud to cable screen screen SystemA ioA ioB Plug shroud to cable screen Figure 2 5 1b Pinout tor Connect module RJ45 type plugs Chapter 2 HA028255 Page 2 10 Issue 2 Nov PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont ELIN CONNECTORS The Connect module contains two pairs of RJ45 type connectors called system A B The left hand pair is for the left hand processo
116. essor file page allowing files to be deleted or copied and the E device to be formatted to display its files up to a maximum of 20 Move the cursor up and down the file list and tag files with an asterisk using lt Enter gt Then move the cursor to the top column head field and press lt Enter gt to display the function menu Copy Delete Find and for E device only Format Finally select a function and press lt Enter gt to carry it out Note that the Find function has wild card characters to help you locate filenames containing known character strings Press lt Escape gt to return to the UTILITIES menu APPLY UNDO UTILITIES Limited database changes can be executed on line from the terminal configurator These changes include making and setting the parameters for blocks and creating and deleting connections Any such changes made whilst the data base is running are provisional and are not applied until APPLY is selected These provisional changes can be discarded by selecting UNDO before APPLY has been selected UNDO has no effect once APPLY has been used Note If changes have been applied and a sync is attempted it will fail unless the primary database has been saved using either the root block s full save option or it is stopped saved and started from the terminal APPLY DCM BLOCKS For DCM blocks not only must the blocks themselves be added to the executing database but also the Communica tio
117. every 6 months The filter should be replaced if any clogging is evident 2 Every two to four years the service consumables listed below should be replaced The recommended replace ment period is a function of the average ambient temperature in which the unit operates At an ambient of 50 degrees Celsius the recommended replacement period is two years For an ambient of 20 degrees Celsius the recommended period is four years The service consumables are available from the manufacturer as a kit which has the partnumber LA028325 Service consunables are a Chassis fan and filter b Battery board c Fan capacitor board Whenever the fan filter is replaced it is recommended that a visual inspection of the interior of the processor unit be made and any deposits of dirt or dust removed using a low pressure compressed air duster such as are available from most electronics distributors 028225 Section 8 Issue 2 Nov Page 8 1 PROCESS SUPERVISOR HANDBOOK 8 2 REPLACEMENT PROCEDURES Note When re fitting the fan ensure that it is oriented correctly with the air flow direction arrow pointing away from the filter i e the airflow is into the unit The arrow is to be found on the edge of the fan body adjacent to the wire aperture Figure 8 2 is a partial exploded view of the processor unit The drawing shows one side plate removed for clarity but this is not always necessary for the procedures below
118. f relays 1 and 2 rl1 and rl2 respectively is entirely software controlled and is set up during configuration The watchdog relay is under hardware control this hardware making a number of health checks before operating the relay If during operation one of the health Coil energisation check fails the relay goes into its alarm power off state See Chapter 3 User under software Interface for full details of the watchdog system control Figure 2 5 1h Relay wiring The relays can be wired in series or in parallel When in parallel both Processors have to fail before the alarm be comes valid When in series the alarm becomes valid if either processor fails Figure 2 5 11 shows the relays wired in series to a 24V healthy lamp Figure 2 5 1 shows a parallel configuration using an auxiliary relay to display both healthy and warning states Note For all relays the common and normally open contacts are open circuit during power off and remain so for some seconds at power up until software control has become established After that the contacts are short circuit when the relay coil is energised and open circuit when the coil is not energised Healthy lamp 12 Watts max 24V left processor right processor Figure 2 5 11 Example wiring for watchdog relays in series 24V dc 240V ac Line Mains relay Com left processor right processor Neutral Figure 2
119. f the timeout has been exceeded the processor will not attempt to restart but will clear the memory and create an empty data base This is called the idle state Note Tepid data is discussed in section 4 2 1 below COLD If cold start is requested the processor will attempt to start from the default data base If this is not possible the proc essor will enter idle mode HOT COLD With the switch set to this position if a hot start is not possible a cold start will be attempted TEST This is normally used only during commissioning or servicing for example under the following conditions 1 First time start up 2 Start up after a new version of system software has been installed 3 Memory configuration has been changed 4 If the processor is to start up but is not yet to run a data base The memory is cleared and a blank data base is created 028225 Chapter 3 Issue 2 Nov Page 3 9 PROCESS SUPERVISOR HANDBOOK This page is deliberately left blank Chapter 3 028225 Page 3 10 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 4 START UP 4 1 4 2 This chapter describes the start up sequence for the unit Topics covered include the differences between redundant and non redundant systems and start mode hot cold etc REDUNDANCY MODES Redundant duplex mode is where two processor units are fitted and are required to act in such a way that one can take over from the
120. fault If the LED is flashing between red off there is a cable or connector fault See also section 3 4 EXP1 EXP2 LEDS These LEDs remain off until the processor module has established communications at which time the LEDs flicker thereby indicating communications activity HA028225 Chapter 4 Issue 2 Nov 03 Page 4 9 PROCESS SUPERVISOR HANDBOOK 4 5 LED FAULT INDICATIONS Cont DUPLEX LED 4 6 If this LED is illuminated green inter processor communications have been successfully established and are running If the LED is flashing green red communications have been established but are not running usually after a de synch request If the LED is off no interprocessor communications have been established usually because the system is non redun dant START UP WITH A CONFIG TERMINAL The configuration port towards the bottom right of the front panel can be used to monitor the start up sequence dis play fault messages etc The start up sequence is unchanged from that described in sections 4 3 and 4 4 of this chap ter above with the following exceptions 4 6 1 M Monitor The operating boot up program includes a diagnostic facility called the M Monitor During the first stages of start up a message Press m key to stop auto boot appears If this message is ignored the Start up sequence will continue as normal if it is accessed within 1 second or for TEST start ups within 10 seconds it allows the u
121. filename is overwritten without warning LOAD Select LOAD and edit the default E T940 GWF if required to the filename to be loaded Press Enter to load the specified configuration An error message appears if the specified file cannot be found Note The current Modbus configuration is overwritten without warning HA028225 Section 5 Issue 3 Jly 04 Page 5 21 PROCESS SUPERVISOR HAN DBOOK This page is deliberately left blank Section 5 028225 Page 5 22 Issue 3 Jly 04 PROCESS SUPERVISOR HANDBOOK CHAPTER 6 ERROR CONDITIONS amp DIAGNOSTICS This chapter describes the various ways to tell if a fault has occurred in the process supervisor not in the process being supervised The main topics covered are 6 1 Error indication types 6 2 Processor module front panel error displays 6 3 Power up failures 6 4 Power on self tests 6 5 Diagnostic blocks 6 6 Error numbers 6 1 ERROR INDICATION TYPES Error indications include LEDs processor module LEDs are the most immediate source of error and instrument status information concerning basic I O system BIOS start watchdog functions and normal running During BIOS start a number of the front panel LEDs are intermittently illuminated to indicate the BIOS status If a processor start fails the pattern that these LEDs adopt prior to the failure is helpful to service engineers so it is rec ommended that this pattern is recorded along with the unit serial number
122. for shutdown gt gt gt 0 0 Register 0x10 disketteO0 set up gt gt gt 1 44 M drive Register 0x10 diskettel set up gt gt gt None Register 0x12 disk set up gt gt gt Disk type gt gt gt 1 Register 0x12 HD1 disk set up gt gt gt None type gt gt gt 0 Register 0x14 bit5 4 Primary display gt gt gt EGA VGA Date gt gt gt DD MM YY Time gt gt gt HH MM SS lt Display gt Y y N n N lt CR gt T Main menu level 0 etc 028225 Section 8 Issue 2 Nov 03 Page 8 17 PROCESS SUPERVISOR HANDBOOK 8 4 8 S MONITOR Cont DIAGNOSTICS MENU The diagnostics menu depicted below is called by typing 4 from the top level menu above phages Diag Menu Level 1 Quit Watchdog register System LED I O LED Serial LED ILOCK WRO Output Read input status Connect the interrupts 5 9 11 12 15 P WATCHDOG REGISTER Accessed by selecting 1 from the diagnostics menu this page displays the following information Watchdog menu ee Level 2 O Quit 1 Bit 7 Enable flash Vpp 2 Bit 6 Flash write protection 3 Bit 5 Redundancy interrupt 4 Bit 4 Watchdog Relay 5 Bit 3 Watchdog Pat 6 Bit 2 Alarm relay 1 7 Bit 1 alarm relay 2 s ma Selection Notes 1 Switching the alarm relays also switches their associated LED 2 Switching the watchdog relay has no effect on the watchdog L
123. g in other LIN instruments Configuration of Serial Comms consists of carrying out one or more of the following 1 Setting the operating mode of the instrument to either Master or Slave MODE 2 Accessing the Tables list which sets register mapping and allows tables to be viewed TABLE 3 Accessing the Utilities menu UTILITIES from which you can SAVE or LOAD protocol configurations Note Master mode is not supported within the configurator 028225 Section 5 Issue 3 Jly 04 5 1 PROCESS SUPERVISO R HAN DBOOK 5 2 1 Configuration Access The Configurator is accessed by connecting the instrument from its Configuration port on the front panel to a VT100 compatible terminal for example an IBM compatible PC running a terminal emulation package 5 3 PREPARING TO RUN THE CONFIGURATOR Getting ready to run the Configurator consists of two main steps 1 Connecting the processor unit to a PC 2 Setting the control efficiency of the instrument 5 3 1 Connecting to a PC The CONFIG port on the primary processor front panel should be connected to the PC RS232 port using a cable fitted with an RJ11 connector at one end and typically a 9 way D type connector at the other Eurotherm part no DN026484 The connector pinouts are detailed in Chapter 2 Installation If further details are required refer to the documentation supplied with the PC Notes 1 To configure a redundant mode instrument
124. gt gt Byte 5 ILOCK_RDO register gt gt gt 24 36 Byte 6 ILOCK_RD1 register gt gt gt 8 8 lt DISPLAY gt Y y N y N lt CR gt a acd Diag Menu etc 028225 Section 8 Issue 2 Nov 03 Page 8 19 PROCESS SUPERVISOR HANDBOOK 8 4 8 S MONITOR Cont CONNECT THE INTERRUPTS 4 Accessed by selecting 7 in the diagnostics menu this page is for use only by the Manufacturer MEMORY STATUS This page is accessed by selecting item 5 from theS Monitor Main menu and presents memory information as fol lows lt Display gt Y lt CR gt Register 0x15 16 Base memory in kbyte gt gt gt 280 640 Register 0x33 Extension memory in kbyte gt gt gt 80 128 Register 0x17 18 Extension memory in kbyte gt gt gt fc00 64512 Total DRAM size in kbyte gt gt gt ff00 65280 lt Display gt n lt CR gt iuda EOS Main menu etc SHOW BOOT INFO This page is accessed by selecting item 6 from the Main menu and presents boot information as follows lt Display gt Y lt CR gt Boot device gt System A Net Boot file gt ide0 S vxWorks Host name gt host s name Target name gt PSE Target IP addr zo LO el eT Host IP addr gt 0 0 0 0 Gateway IP addr gt lt Display gt n lt CR gt mE Main menu etc DATE TIME SET Accessed by selecting item 7 from the main me
125. gt to repeat lt SPACE gt for next Each operation of the space bar followed by a carriage return initiates the next test Test 1 measures how long it takes to write data to flash If this exceeds 140 ms the Compact flash device should be replaced because tepid data may not be stored successfully causingsubsequent hot tepid start failure Tests 2 to 4 check the operation of the three relays by opening their contacts for one second closing them for 1 sec ond opening again for 1 second closing again Open status is indicated by an LED WATCHDOG RELAY TEST Open Close the watchdog relay twice at 1 second per state Duplex LED illuminated whilst relay contacts open Section 8 HA028225 Page 8 14 Issue 2 Nov PROCESS SUPERVISOR HANDBOOK 8 4 7 AUTOMATIC SET UP Cont RL1 RELAY TEST Open Close the relay RL1 twice at 1 second per state RL1 LED illuminated whilst relay contacts open RL2 RELAY TEST Open Close the relay RL2 twice at 1 second per state RL2 LED illuminated whilst relay contacts open COMMUNICATIONS HARDWARE CHECK The unit autodetects whether arcnet and profibus cards are fitted and creates a config txt file 028225 Section 8 Issue 2 Nov 03 Page 8 15 PROCESS SUPERVISOR HANDBOOK 8 4 8 The S Monitor Note The S monitor is intended only as a diagnostic tool for Commissioning and or Service Engineers Because of the unit s safety critical requirements acce
126. hat can arise with inadequate cabling it is strongly recommended that ready made interconnecting cables are ordered from the manufac turer Chapter 2 HA028255 Page 2 14 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Continued DC SUPPLY WIRING Each processor has two 24V supply connections A and B near the bottom of the Connect module front panel The unit will operate on any dc voltage between 18V and 36V at a maximum power requirement of 50W per processor module In addition to this a separate connector allows an external battery of between 2 5 and 5 0V to be connected to maintain the real time clock Typical drain currents are 0 2 mA at 2 5V and 0 3 mA at 3 4V Recommended power supply units and batteries are listed in Chapter 9 A nickel metal hydride battery board can be supplied inside each processor unit When fully charged this will main tain the Real time clock data for a minimum of 72 hours should an external battery not be available during power down or if the Connect module is removed from the backplane The battery is supplied partially charged but it is recommended that the processor unit in which it is fitted be left powered continuously for 48 hours to ensure full backup capability Figure 2 5 1g shows the locations of the connectors and gives recommended conductor sizes based on current carrying capability and connector capacity Caution 1 Neither the positive nor the negative supply lin
127. herm ALin Process supervisor Terminator Project Studio I O A Unused ports B need terminators 7 a 5 Remote 1 0 A Terminator tJ Figure 2 5 1f Daisy chain layout HA028225 Chapter 2 Issue 2 Nov 03 Page 2 13 PROCESS SUPERVISOR HANDBOOK 2 5 1 CONNECT MODULE Cont ALIN HUBS PASSIVE Mechanically a passive ALIN hub consists of a metal box with 12 RJ 45 type connectors and one RJ11 connector for earlier equipment Electronically the hub consists of a resistor network designed to allow each of the 12 ports to be connected to a single unterminated node using a cable up to three metres in length Cable termination is provided by each port and vacant ports must be left unterminated This system ensures survival with one port short circuited and any number up to the maximum of open circuit ports DAISY CHAIN LAYOUT This method of connection is the preferred method where the integrity of the network is certain Further details are to be found in the LIN ALIN ELIN Installation and user guide 0824290005 CABLING Shielded RJ45 connectors and screened Category 5 cables are widely available Note however that specifications vary and not all components are suitable for reliable ALIN operation In view of the problems t
128. ilst higher priority tasks execute Rapidly fluctuating repeat times for the lower priority tasks usually indicates an attempt to allocate too much total CPU time to the user tasks A slight increase in some or all of the TaskRpN values should cure this The percentage CPU power allocated to the four user tasks should total approximately 80 to 90 PS TASK displays units of 0 1 If the sum is less than this it should be safe to reduce TaskRptN values Note It is recommended that the engineer enters appropriate TaskRpN values Setting unrealistic values will cause erratic task repeat rates HAO28225 Chapter 7 Issue 2 Nov 03 7 5 PROCESS SUPERVISOR HANDBOOK 7 4 DATA COHERENCE 7 4 1 Data flow between tasks Coherence is an important aspect of control strategies involving more than one user task Data flow is defined as being coherent if during any single execution of a task the data input into it from outside the task is a snapshot unchang ing during the execution of the task and represents the values output from other tasks that have completed their ex ecution Data coherence by definition refers to connections that are remote i e linking different tasks Connections that are limited to within a task i e local are simply dealt with by being copied from source to destination immediately before executing the destination block For any task there are three important types of remot
129. in configuration ALIN only or a central ALIN or ELIN hub See Chapter 2 figure 2 5 MODBUS The Unit supports Modbus comms via the connect module master and exp 2 slave ports if so configured PROFIBUS The Unit supports Profibus communications via the connect module 1 port REDUNDANT PROCESSOR MODULES The processors can be set up for redundant or non redundant operation When operating in redundant duplex mode a high speed data link ICM between the primary and secondary processor units provides exact tracking of the con trol database allowing bumpless takeover by the secondary unit should the primary processor fail Note See the Important Information leaflet HA261399 for backwards compatibility details AUTOMATIC TAKE OVER Takeover of control by the secondary processor in the event of primary failure is automatic with no loss of I O states and no need to re initialise I O points Revalidation of all attached LIN nodes is automatic REDUNDANT POWER SUPPLY CONNECTION Two independent power connectors for each processor unit plus external battery for memory backup ensures full redundancy An internal battery supports the data in SRAM if fitted and the real time clock for a minimum of 72 hours LIVE PROCESSOR REPLACEMENT Live replacement of a failed processor can be carried out with no wiring disconnections The replacement unit loads its strategy and current status from the active processo
130. induce vomiting Give plenty of milk to drink Obtain 9 immediate medical assistance stating nickel metal hydride battery Inhalation Not applicable REACTIVITY DATA STABILITY Conditions to avoid Mechanical damage overcharging short circuiting terminals Stable Yes Unstable charging temperatures outside the range 0 to 65 C direct soldering Hazardous decomposition None products Hazardous polymerisation Will not occur SPILL OR LEAK PROCEDURES In normal use there is no risk of leakage If batteries are abused this may lead to the leaking of a caustic alkaline solution which will corrode aluminium and copper The leak material should be neutralised using a weak acidic solution such as vinegar or washed away with copious amounts of water Contact should be avoided DISPOSAL Batteries must be disposed of according to current local regulations Batteries should not be discarded with normal refuse SPECIAL PROTECTION INFORMATION Respiratory Not applicable Ventilation Not applicable Protective clothing Not applicable Other HA028255 Section 9 Page 9 8 Issue 04 PROCESS SUPERVISOR HAN DBOOK IN DEX Symbols C Cont rete ERR 4 2 are 5 7 FED file ihidem 4 2 Conductive pollution 2 2 24 Volt WINING etes 2 15 Configuration 32 bIt register
131. is allows the status of the comms link between the nodes to be monitored from both ends via the cached blocks soft ware alarms This bidirectional caching also eliminates the fleeting software alarms that may otherwise be seen during processor changeover in a redundant mode system Select NETWORK from the main menu to display the Network setup page initially blank Figure 5 5 5 shows the top part of an example page with several databases already assigned Network setup Alpha sor 07 ov Beta gt 02 dBase 1 gt 03 Figure 5 5 5 NETWORK setup page example To assign a new database name and address locate the underline cursor at the left hand column of a blank row type in a unique name 7 characters max and press Enter The name appears added to the list together with a default node address 200 Non unique or invalid names are beeped and not accepted Do not use 00 or FF as node addresses Move the cursor to the default address and type in the required node address two hex digits Press Enter to com plete the assignation To edit an existing name or address locate the cursor at a field type in the new value and press Enter Invalid entries are not accepted To delete a complete name and address entry edit its name field to a space character Configurations downloaded from LINtools will have a Network page set up automatically 028225 Section 5 Issue 3 Jly 04 Page 5 13 P
132. is enabled the configurator Initial menu appears as shown in figure 5 4 16 If Modbus is disabled the Main menu appears instead as shown in figure 5 5 Modbus in enabled disabled by means of the Options switch SW2 on the backplane as described in section 2 4 2 INIT Choose option gt DATABASE General configuration GATEWAY MODBUS configuration Figure 5 4 18 Configurator initial menu Note If the Initial or Main menu appears this indicates that the Processor module has entered configuration mode Locate the cursor gt at a menu item using the cursor keys then press lt Enter gt to display the next level in the menu hierarchy This is called selecting an item In general to access the next lower level of the menu hierarchy lt Enter gt is pressed To return to the next higher level menu or close a pop up options menu the lt Escape gt key is pressed lt PageUp gt and lt PageDown gt allow hidden pages in long tables to be accessed For keyboards without cursor control keys equivalent control character combinations may be used as indicated in Table 5 4 1 To use these the lt Ctrl gt key is held down and the specified character typed Function Key combination Clear screen lt Ctrl gt W Cursor Up Ctrl U Cursor Down lt Ctrl gt D Cursor Left Ctrl L Cursor Right Ctrl Page Up Ctrl P Page Down Ctrl N Stop automatic update Ctrl V
133. isplays current setting None Odd or Even Stop bits Displays the current setting 1 or 2 Time out Displays the Time out value in the range 0 to 65 5 seconds In slave mode this parameter specifies a timeout period for all tables That is if a table has not been accessed for Time out seconds the Online bit in the slave mode diagnostic register for that particular table resets to zero In master mode Time out specifies a maximum period between the end of a master s request for data to the start of the slave s response If this time is exceeded the Online bit in the master mode diagnostic register for the particular table concerned resets to zero Slave No Slave operating mode only Displays the Modbus address of the slave device being configured Slave addresses are in the range 01 to FF but for some equipment FF is invalid When SETUP viewing is complete press lt Escape gt return to the Gateway menu Any changes will be ignored HA028225 Section 5 Issue 3 Jly 04 5 17 PROCESS SUPERVISOR HAN DBOOK 5 6 3 Tables To view the tables list highlight TABLES and press lt Enter gt TABLES LIST The tables list provides an overview of the sixteen tables in the Modbus configuration through which tables are cre ated and their types offsets sizes and for master mode function codes scan counts and slave numbers are specified The tables list also accesses individual table menus for detailed configura
134. its in the database automatically copy the edited unit Pressing Enter with the field selected before starting to type accesses the parameter Full Description page as for the value field 028225 Section 5 Issue 3 Jly 04 5 9 PROCESS SUPERVISO R HAN DBOOK 5 5 1 MAKE Cont 4 Options menu fields Press Enter to display a pop up menu of options for the field Figure 5 5 1e shows an example PID Mode in part of an overview page OVERVIEW Block PID 1 Type Mode itl Fallback gt HOLD eee PV ANUAL g SP 51 OP hee SL F MAN 9 TrimSP F AUTO g RemoteSP ea 9 Track PID DBase Alarms HAA 100 LAA 0 0 HDA 100 LDA 100 TimeBase XP 100 0 TI 0 000 TD 0 000 Eng Eng Eng Eng secs 9 Figure 5 5 1 Pop up options menu example Using the arrow keys move the cursor gt to a menu option and select it by pressing lt Enter gt Disabled op tions may not respond to selection A quicker alternative to accessing the pop up options menu is to type the required option or enough of its initial letters to uniquely specify it directly into the selected field and then press lt Enter gt E g entering just H selects HOLD entering F_M selects MAN Forced Manual 5 Alarms field Press lt Enter gt to display a 4 column Alarms page listing alarm name e g HighAbs acknowledgement
135. iven to the table via the tables list The remaining read only addresses follow on according to the numbers of bits on each successive line of the table 1 8 or 16 This is the LIN database field which can be mapped onto the Modbus address or left blank Select a field with the cursor and type in and enter a block name plus parameter and subfield if needed separated by full stops periods e g PV1 Alarms Software Note that if an attempt is made to enter an analogue parameter into a digital table Field the entry is ignored Any type of parameter can however be entered into a register or diagnostic table Note also that in a digital table database parameters cannot be entered or overwritten if to do so would force an entry lower down the table to change its address Digital value Register and diagnostic tables only This column can be used for either of two functions specifying a decimal point position or creating a 32 bit register Decimal point position Represents the number of decimal places 0 to 4 inclusive to be used when con verting floating point numbers to 16 bit Modbus registers 32 bit register Register tables only A 32 bit register is created by joining a consecutive pair of 16 bit registers as described below Note the restrictions that are applied to ensure that the 32 bit value created is transferred indivisibly a The multiread function 3 and multiwrite function 16 must both be enabled b Thesca
136. ks Applicable only when using ELIN Every 10 msec approx Network Housekeeping for all transactions over the LIN Event driven NFS Network Filing system Processes LIN filing requests Event Driven PMC Profibus Master Comms Responsible for all transactions with profibus devices Profibus cycle time File Sync Responsible for maintaining synchronisation of filing systems on redundant systems Event driven Mod Rx Processes messages received via GW Modbus Event driven Modserv Modbus database management Periodic User Task Runs user tasks 1 to 4 Every TaskRptn secs Note 2 Cache Sync Server Responsible for maintaining synchronisation of cached blocks Every 100 msec approx Cache Conn Server Responsible for connections into cached blocks i e LIN network field writes Every 100 msec approx LLC Monitors LIN link low level status Applies timeouts to transmitted messages Re programs LIN hardware if errors are detected Every 100 msec approx Pr Maint PRP database management applicable only when using ELIN Every 500 msec approx Load Loads a database on remote request Event driven 20 AMC x2 Application master comms Processes communications with modbus or profibus devices via DCM blocks Event driven 21 Config Runs the terminal configurator Event driven 22 BatLoad Responsible
137. les the processor modules are said to be synchro nised SFC Sequential Function Chart An SFC monitors key variables and parameters and on the basis of the values it finds decides which route through a flowchart the application should follow Simplex A processor working alone i e in non redundant mode SLIN LIN protocol on a serial link point to point Tepid Start Similar to a hot start but with a only limited amount of database information Test start Once started the processor module enters an idle mode with an empty data base loaded Section i HA028225 Page i 10 Issue 04 PROCESS SUPERVISER HANDBOOK CHAPTER 1 INTRODUCTION The process supervisor is one part of a complete control system The entire package is described in the Eurotherm Project Studio User Guide and Tutorial HA261230 which includes a number of tutorial examples to help users to familiarise themselves with the software and hardware facilities available 1 1 MANUAL CONTENTS 1 2 This manual is divided into the following chapters Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Introduction Installation User Interface explaining the front panel LEDs and switches Start Up step by step instructions on how to start up or re start the instrument Configuration how to configure or more typically re configure control strategy and communications protocols on site usually to match ch
138. ment header block includes a CPF alarm to indicate if any problems were encountered whilst executing the CPF file Sample CPF file Production plant Cold Start Initialisation CPF file Ensure no automatic control until started PIC 023 Mode Manual XCV 124 Mode Manual Ensure vent valves open XCV 124 Demand False Open XCV 123 Demand False Open Reset profile to default Profile A0 23 4 Start temp Deg C Profile Al 34 5 First target temp Deg C Profile A2 2 0 Ramp rate Deg C min Initialise totalisation block gt COUNT 01 NTotal 10 gt COUNT 01 NTotFrac 0 5 Chapter 4 HA028225 Page 4 2 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 4 2 START UP MODES Cont 4 2 3 cold start This setting causes the unit to attempt a hot start If the hot start fails however instead of going straight into idle state as with hot start the unit attempts to carry out a cold start If the cold start fails the data base will be cleared and the processors enter an Idle state and remain there until physically restarted 4 2 4 Test start Test start means that the instrument starts up with that part of the memory which holds the database cleared set to zero throughout A Test start is normally requested 1 atthe very first start up in the life of an instrument
139. mounted Invalid device Physical error Not implemented Format error Not present Device full File not found No handle Bad filename Verify error File locked File read only or No key fitted Unable to perform file check Unable to defer another file during synchronisation Illegal combination of open flags Couldn t complete file operation as synchronisation is in progress File cannot be modified Failed to duplicate file operation No handle to duplicate queue File systems no longer synchronised Synchronisation aborted Response length error File system timeout File synchronisation not requested Duplicate on secondary rejected Non specific error Sync fail due to DBF check Sync fail due to DBF load file name error Drive letter already assigned Filing out of memory Illegal link drive letter No such link exists Read write file transfer to large Read file error Write file error Table 6 2 2a File system error codes 82xx Bad template Bad block number No free blocks No free database memory Not allowed by block create In use Database already exists No spare databases Not enough memory Bad library file Bad template in library Bad server Cannot create EDB entry Bad file version Bad template spec Unable to make block remote Bad parent Corrupt data in DBF file Corrupt block spec Corrupt block data Corrupt pool data No free resources Template not found Template resource fault Cannot
140. mple Block tagname Read write Block type Read only Time secs since the block was last scheduled to run Note that for a control block the PID algorithm is not necessarily recalculated every time the block is scheduled Read only Block s time scheduled task priority Read write There are four User Tasks numbered from User Task 1 highest priority to User Task 4 lowest priority See Chapter 7 for more details Name of the block s parameter database A blank field means the block database is local i e in the current processor Database names and their LIN addresses are specified via the main menu NETWORK option described in section 5 5 5 Read write For cached blocks Rate is the minimum update period i e maximum rate at which an individual cached block is transmitted across the Local Instrument Network LIN The default is 10ms minimum i e 100Hz maximum Rate can be set between 10ms and 64s Note that rate values are minimum update times only and heavily loaded networks may not be able to reach the faster update rates For DCM blocks Rate is the target period at which the block s data is to be updated via Modbus A minimum value of 1000 ms is normally needed The default value of 100ms is accept able for Profibus working but can cause problems with Modbus This is the time taken in microseconds to execute a block including connections etc Section 5 5 8 HA028225 Issue 3 Jly 04 PROCESS
141. mplete then as a minimum the Power and wdog LEDs are illuminated continuously green The primary LED will be illuminated continuously if a data base is running or it will flash if a data base is not running The COMMS system LEDs will also be illuminated green if the associated comms links are operating correctly or Red steady or flashing if not In addition if any other communications are in progress the relevant LEDs will be illuminated either continuously or intermittently See Section 3 4 for more details of the communications LEDs If back up batteries are fitted the int and ext LEDs are illuminated as appropriate 4 3 2 Watchdog indications The watchdog LED has four modes of operation 1 Steady green In this state either the processor is running with no detectable hardware or software faults the cooling fans are working and the processor temperature is within its working range or one of the Monitors has been accessed see section 4 6 2 Steady Red When continuously red a hardware or software fault has developed see section 4 5 below 3 Long red short green flash This occurs at the beginning of the start up procedure whilst the status of the fans and the temperature of the central processing unit are checked 4 Long green short red flash This indicates that the fan status and temperature measurement were acceptable and initialisation is continuing correctly This mode remains active until the start up proce
142. n be supplied in a range of enclosures both wall mounted and floor standing Power sup plies standard terminations transmitter power supplies and I O modules can all be fitted within these enclosures and if required a visual supervisor unit can be door mounted to allow a visual representation of process variables multiple E Hi p Li mcr Process supervisor Figure 1 3 2c Typical installations Note The process interface i o modules can be mounted vertically as shown in the sides of the single bay enclosure or horizontally as shown in the two bay version HA028225 Chapter 1 Issue 2 Nov 03 Page 1 3 PROCESS SUPERVISER HANDBOOK This page is deliberately left blank Chapter 1 HA028225 Page 1 4 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 2 INSTALLATION This chapter presents safety and EMC information and describes the mechanical and electrical installation of the in strument The main topics covered are as follows Safety amp EMC information section 2 1 Unpacking section 2 2 Mechanical layout section 2 3 Set up switch definition section 2 4 Connections and wiring section 2 5 2 1 SAFETY AND EMC INFORMATION Please read this section before installing the unit This unit meets the requirements of the European Directives on Safety and EMC as detailed on the Declaration of conformity IA249986U610 a copy of which appears at the beginning of this manual
143. n count must be even c The first register of the pair must be at an even offset within the table d first register of the pair must not be the last register in the table e The second register of the pair must not already be assigned to a database field f field type of the 32 bit register pair must be 32 bit long signed or unsigned 32 bit real or a string For a string only the first four characters are transferred To create a 32 bit register pair enter d or D in the DP field of the first register of the pair This causes the register s DP to adopt the value D and the following register the value d If any of the above restrictions are violated the entry will be rejected When the first register of the 32 bit pair is assigned to a database field the second register automatically copies the same field name assigning the name and the DP can be done in either order You can restore a 32 bit register pair to individual 16 bit registers by changing the first register s DP to 0 to 4 Register and diagnostic tables only This column specifies the format of the data in the register as normal or BCD binary coded decimal Normal format means that the data is a simple 16 bit integer In BCD format the value is first limited to the range 0 to 9999 and then stored as four 4 bit nibbles in the register The units are stored in the low order nibble the tens in the second nibble the hundreds in the third a
144. nbuilt configurator and a dumb terminal EUROTHERM PROJECT STUDIO Control strategies and sequences to be run in a Process Supervisor may be configured and downloaded using the Eu rotherm Project Studio which is fully described in the documentation supplied with it Information is also available via the Eurotherm network explorer The LIN Product Manual Part HA082375U999 should be consulted for details of the function blocks that can run in the Process Supervisor TERMINAL CONFIGURATOR RESTRICTIONS The use of the configurator is restricted according to the operating mode of the Process Supervisor in the following ways 1 The terminal configurator can be used only on the primary processor module 2 The database must not be running if you want the full capability to create blocks databases edit field values and modify pool data e g engineering units If it is running the configurator can write only to the normally runtime writeable fields e g block names cannot be edited but new blocks may be added and new wires can be made on line These restrictions prevent files or edits occurring in the primary database that cannot be tracked by the secondary database Note When the database is started after the terminal configurator has been used an automatic database save is performed This ensures that any changes are notified to the secondary CPU during synchronisation 2 5 3 Safety earth connection As shown in figure
145. nd for selecting options on and off are revealed figure 2 4 1 when the right hand processor module or the cover plate is removed from the back plane 2 4 2 Switch functions SW 1 LIN ADDRESS SETTING SWITCH Figure 2 4 2a below shows the LIN address setting switch SW1 located on the backplane as shown in figure 2 4 1 The figure shows a sample set up for address pair 7A 7B Whenever there are two processor modules fitted to the backplane and working in non redundant mode the left hand processor unit is allocated the even address Bit 0 0 and the right hand processor is allocated the odd address Bit 0 1 When working in redundant mode the primary processor is initially the left hand even address unit and the second ary is initially the right hand odd address unit Should it prove necessary for the secondary to take over and become the primary it will also take over the even address Note In redundant mode a single processor module running on its own in the chassis never adopts the odd address as it is always the primary controller It is strongly recommended that this odd address be kept spare and not allocated to another instrument on the same LIN segment This will avoid address clashes if a second processor module is subsequently added to the backplane Figure 2 4 2a LIN address setup example Lr d 4 Sw1 LIN Address 7 A B 101X SW1 ADDRESS 81 r ON tea
146. nd the thousands in the high order nibble BCD format allows the data to be used with certain devices such as displays Note Format is ignored in 32 bit registers Digital tables only This column indicates the number of bits contained in the associated field The default Width is 16 but it automatically updates when a parameter is allocated to the field Allocated field widths are read only but the width of an unallocated field can be edited by highlighting its Width value and entering a number in the range 1 to 16 normally 1 8 or 16 Note that a Width value cannot be edited if to do so would force an entry lower down the table to change its address Digital value Section 5 Page 5 20 HA028225 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 6 3 TABLES Cont DB Write MOD Write Value This column allows selected values in the LIN database to be protected from being overwritten by values received across the serial link Highlight the required DB Write field and press Enter Select Protect to write protect the LIN database parameter or Enable to allow overwriting Note For a 32 bit register pair DB Write applies only to the first register The DB Write value of the second register is ignored This column allows the user to prevent selected values in the LIN database being written to their associated Modbus registers or bits Highlight the required MOD Write field and press Ent
147. ndo the four 4mm 7mm AF fan securing nuts C and ensuring all fixings are retained remove the nuts and washers and lift the fan off its studs and discard it 4 Remove the fan filter and replace it with a new one 5 Replacing all the washers previously removed fit the new fan and secure it using the M4 nuts C 6 Slide the lower panel back into place carefully ensuring that the fan cable harness is not damaged in the process and re make connector D 7 Re assemble the module as described in section 8 2 1 steps 10 to 12 above 028225 Section 8 Issue 2 Nov 03 Page 8 3 PROCESS SUPERVISOR HANDBOOK 8 2 3 Capacitor board capacitor board fan replacement Note When fitting the fan ensure that it is oriented correctly with the air flow direction arrow pointing towards the circuit board The arrow is to be found on the edge of the fan body adjacent to the wire aperture Prepare the module by carrying out steps 1 to 4 of section 8 2 1 above Disconnect the capacitor board connector F in figure 8 2 Disconnect the capacitor board fan from the PSU board connector E in the figure Remove the two M 3 screws securing the support plate to the circuit board stack retaining all fixings Carefully remove the support plate and place it safely to one side for use in re assembly Remove the remaining two M3 screws securing the capacitor board to the stack and lift the board out of the
148. ns parameters must be passed to the AMC data groups For Profibus blocks 1 DCM block must refer to a Profibus node that is already known to the system I E There must already be other running DCM blocks referring to the node If the node is not known the DCM block enters Config Alarm and a suitable error mesage is added to the UYC file 2 The new communications parameters are added for Acyclic operation only The database must be restarted or a changeover must be forced on a synchronised unit in order to install the parameters for Cyclic use The restrictions above do not apply to Modbus blocks HA028225 Section 5 Issue 3 Jly 04 Page 5 15 PROCESS SUPERVISO R HAN DBOOK 5 5 6 UTILITIES Cont ELIN SETUP This page allows the instrument s network unh file to be configured from a user friendly interface rather than by direct file editing Elin Setup network unh file LIN PROTOCOL SETUP REMOTE SUBNET NODE LIST Protocol Name RKN 1494 1214 173 1 All Subnet Enable OFF Elin Only Enable ON LOCAL IP SETUP Get Address Method Fixed IP Address 149 121 128 209 Subnet 255 255 252 0 Default Gateway 149 121 128 138 LIN PROTOCOL SETUP This area of the screen allows specification of those items in the LIN section of the network unh file LOCAL IP SETUP Allows the specification of those items in the IP section of the network unh file The IP
149. nt After a power loss the instrument attempts to re start with the current database still loaded and with all parameters and values for that application still at the values they held when processing stopped If the restart fails the processor enters an idle state After a power loss the instrument attempts to re start with the current database still loaded and with all parameters and values for that application still at the values they held when processing stopped If the restart fails the processor attempts a cold start ICM Inter CPU Messaging for redundancy Idle A state in which the processor module is powered up but with an empty database This state is entered as a result of being selected as start up mode or if a hot start or cold start is not successful IP Internet Protocol iTools A Eurotherm utility for configuring networks of Eurotherm I O controllers HA028225 Section i Issue 3 04 i 9 PROCESS SUPERVISOR HANDBOOK GLOSSARY Cont LIN LIN database LIN protocol LINtools Modbus Non redundant mode PAL Primary Processor module Process variable Profibus PSU Redundant mode Local Instrument Network a Eurotherm proprietary system for networking process monitoring and control instruments The LIN database is a set of software function blocks that constitute the control strategy of a LIN instrument The communications protocol employed to control instruments linked by a LIN A
150. nu this allows the user to set the date and time Section 8 HA028225 Page 8 20 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 9 SPECIFICATION ABD ORDER CODES INSTALLATION CATEGORY AND POLLUTION DEGREE This product has been designed to conform to BS EN61010 installation category II and pollution degree 2 These are defined as follows Installation category Il The rated impulse voltage for equipment on nominal 230V ac mains is 2500V Pollution degree 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by con densation shall be expected HAO28255 Chapter 9 Issue 3 Jly O4 Page 9 1 PROCESS SUPERVISOR HANDBOOK 9 1 SPECIFICATION This specification defines the Process supervisor components Backplane Connection Module Processor Module 9 1 1 General specification Physical Dimensions Backplane Connection Module Processor Module Backplane fixing centres Weight Backplane without modules Connection module Processor module 402mm wide x 180mm high x 24mm deep 120mm wide x 180mm high x 126mm deep 120mm wide x 180 mm high x 186mm deep 382 horizontal x 125 vertical 2kg max 1 1kg max 2 4kg max each Environmental Temperature Storage Operation Humidity Storage Operation RFI EMC emissions EMC immunity Safety Specification Vibration 25 to 85 C O to 50 C 5 to 95 RH non condensing BS EN61326 2002 02
151. number serial number and hardware build level 3 Software labels showing version and issue numbers 4 Flash memory card label showing version and issue number 5 Safety earth symbol adjacent to safety earth stud MECHANICAL LAYOUT AND INSTALLATION Figure 2 3 1a shows two processor modules and a connect module mounted on the backplane Remote I O modules described in the 2500 Controller User Manual HA026178 are connected to the processor modules using the i oA and or i oB communications sockets of the connection module Figures 2 3 1b and 2 3 1c show front views of the modules When only a single processor is fitted it is recommended that the blanking plate supplied be fitted to the vacant slot to maintain EMC emission immunity specifications The processor modules can operate either independently simplex or else in redundant duplex mode in which case one of the processors acts as a primary backed up by the other processor the secondary which can take over from the primary at any time Power is supplied to each processor module by one or two external 24V nom power supplies The two supplies are effectively OR d together within the processor module so they can run in parallel thus ensuring that the processor continues to operate even if one of the supplies fails A separate plug is available to allow the connection of an external battery 2 4 to 5 0 V to maintain the real time clock RTC during shut down An int
152. ocess to an unacceptable degree A brownout time can be set in the root block and if power to the unit is lost for this duration or longer the brownout alarm will be set also in the root block This brownout time can be defined as the maximum duration of power loss that can be tolerated by the process without reinitialisation being necessary For this unit if the Hot start fails because the data base is corrupted or because the Cold Start Time has been ex ceeded the data base will be cleared and the processors will enter an Idle state and remain there until physically restarted See also Hot Cold start Note If a hot start occurs the last loaded database file RUN stored in EEPROM is used overlaid with tepid data Tepid data is described in the following section HA028225 Chapter 4 Issue 2 Nov 03 Page 4 1 PROCESS SUPERVISOR HANDBOOK 4 2 1 HOT START Cont TEPID DATA At the end of each task iteration a package of data is assembled in a TPD file in RAM ready to be written to FLASH should a power down occur This tepid data includes each loop s local setpoint SL output OP and operating mode MODE In the event of a power down providing that the data file does not exceed 10kB in size there is enough time for the tepid data in the TPD file to be transferred rapidly to FLASH ready to be used if required during a subsequent hot start routine The tepid data is coherent see Section 7 4 bec
153. ode Transmit failure Failed to get memory Decode packet Remote file system busy Illegal TEATT Wrong TEATT NServer is busy TEATT not owned Duplicate block TEATT rejected Port disabled No port configuration Bad network filename Network node invalid Table 6 6 2g Sequence data base system error codes 8Bxx 8 01 Database not Running 8 02 No Sequences Loaded 8C03 Sequence is being displayed 8C04 Cannot find an SFC DISP block 8 05 Cannot find Source File 8 06 Sequence Not Loaded Table 6 6 2f Network error codes 89xx Table 6 6 2h Sequence runtime error codes 8Cxx HAO28225 Issue 2 Nov 03 Chapter 6 Page 6 15 PROCESS SUPERVISOR HANDBOOK 6 6 2 ERROR MESSAGES Cont 8D01 Syntax Error 9901 No EDB s left 8D02 Statement expected 9902 EDB already exists 8D03 Assignment expected 9903 Invalid EDB 8D04 THEN expected 8D05 ELSE or END IF Table 6 6 2m External data base errors 99xx 8D06 END IF expected 8007 expected 8008 Bad bracket matching 9A01 Invalid Second Register 8009 Identifier too long 9A02 Nota 32 bit field type 8DOA Bad identifier 9A03 Invalid Scan Count 8DOB Unrecognised symbol 9A04 Incorrect Modbus function types 8DOC Code Buffer Full 9 05 Invalid register position 8DOD Expression expected 9A06 Second register of 32 bit pair 8DOE Can t find this name 9A07 Invalid register type 8DOF String gt 8 chars 8D10 End quotes expec
154. ont Power A Diagnostic Value Main power input valid Main power input failed Power B Auxiliary power input valid Auixiliary power input failed backup ext External battery power valid Off until start up External battery power faile complete backup int Internal battery power valid Off until start up Internal battery power failed complete Alarm active Alarm not active Alarm active Alarm not active System A communications valid System A communications hardware failure System A communications cable fault System A communications not in use System B communications valid System B communications hardware failure System B communications cable fault System B communications not in use A communications valid A communications hardware failure A communications cable fault A communications not in use B communications valid Flashing Green off Remote unit fault Profibus comms only B communications hardware failure B communications cable fault B communications not in use Exp1 Tx Rx Intermittent yellow Communications taking place Exp2 Tx Rx Primary Intermittent yellow Communications taking place This CPU is primary This CPU is not primary Powered up but no database is running Standby This CPU is secondary and synchronised This CPU is not secondary synchronised Synchronisation process in progress wdog CPU not in
155. ont panel as described above 5 For more information refer to the iTools User Manual part 026179 A ls Modbus Ethernet Master TCP IP OR Modbus DCM Master Note The Modbus switches are con trolled via the _system opt file as described in the Comms Manual HA028014 2500 Slave 2500 Slave Figure 2 5 4 TMA schematic Chapter 2 HA028255 Page 2 20 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK CHAPTER 3 USER INTERFACE 3 1 INTRODUCTION This chapter describes the functions of the processor module LEDs and switches As shown in figure 3 1 the items are arranged in groups on the processor module front panel and each group is de scribed in turn below Table 3 1 below is a concise list of the LEDs and their functions Process ipic EUROTHERM Processor surte POWER ALARMS 24 i Section 3 2 Section 3 3 battery m COMMS system expl Section 3 4 tx rx i o O O exp2 ex PRIMARY O STANDBY Section 3 5 sync Q changeover desync Q Section 3 6 RESTART O CONFIG ot hot cold Id e LZ halt C duplex Figure 3 1 Processor module front panel 028225 Chapter 3 Issue 2 Nov Page 3 1 PROCESS SUPERVISOR HANDBOOK 3 1 INTRODUCTION Cont Diagnostic Value Ch 6 Power A Main power input valid Main power input failed Auxiliary power input
156. or specification For terminals specified as having no isolation the maximum permissible voltage is 30V ac or 50 V dc CONDUCTIVE POLLUTION Electrically conductive pollution e g carbon dust water condensation must be excluded from the enclosure in which the unit is mounted To ensure the atmosphere is suitable an air filter should be installed in the air intake of the en closure Where condensation is likely a thermostatically controlled heater should be included in the enclosure VENTILATION Ensure that the enclosure or cabinet housing the unit provides adequate ventilation heating to maintain the operating temperature of the unit within the limits indicated in the Specification see Chapter 9 PRECAUTIONS AGAINST ELECTROSTATIC DISCHARGE Caution Circuit boards inside the units contain components which can be damaged by static electrical discharge Before any circuit board is removed or handled it should be ensured that the handler the instrument and the circuit board are all at the same potential 2 1 3 Keeping the product safe To maintain the units in a safe condition observe the following instructions MISUSE OF EQUIPMENT Note that if the equipment is used in a manner not specified in this handbook or by Eurotherm Process Automation the protection provided by the equipment may be impaired SERVICE AND REPAIRS Except for those parts detailed in Chapter 8 the Process Supervisor has no user serviceable parts Contact th
157. ostic This is a special table similar to a register table but the values in the table have pre defined values that are used to control Modbus operation or present diagnostic information to the database Selects the start address of the table on the Modbus network The values used here are the actual values used in the address field of the Modbus messages i e the protocol addresses Note that PLCs differ in the correspondence between their register or bit addresses and the protocol addresses This field specifies the number of registers or bits in a table It allows the size of register and digital tables to be changed from their default values of 64 registers or bits respectively to optimise the use of memory Diagnostic tables are fixed at 32 registers Section 5 Page 5 18 HA028225 Issue 3 Jly 04 PROCESS SUPERVISO R HAN DBOOK 5 6 3 TABLES Cont Functions Scan count Slave No Master mode only This field allows the default Modbus function codes that can be used with a particular Modbus table type to be enabled and disabled Modbus function codes define the type of data exchange permitted between master and slave instruments via a particular table To disable a default function code highlight it with the mouse and press Enter to see a menu of and the default code number Selecting and entering disables that code for the table concerned Select the code number again to re enable it if requi
158. protocol error Modbus exception recvd Tx fail Table 6 6 24 Locks error codes 9 Table 6 6 2w MMC error codes 4 HAO28225 Issue 2 Nov 03 Chapter 6 Page 6 17 PROCESS SUPERVISOR HANDBOOK 6 6 2 ERROR MESSAGES Cont A601 Asynchronous I O in progress A602 No asynchronous I O in progress A603 Not yet implemented transferred A606 Event not unique A607 General CIO error A608 No asynch operation fetched A609 Out of serial lines A60A Unable to allocate the requested line A60B Failed to submit asynchronous I O A60C Input output timed out A60D Indeterminate error during fetch A604 Tx operation complete but not all characters A605 Rxoperation complete but not all characters received AG60E I O timed out but failed to cancel operation in progress Table 6 6 2x Asynchronous 1 error codes ADO1 Cyclic data not available 02 Cannot make cyclic into acyclic ADO3 Profibus not allowed AD04 Profibus C2 not allowed ADO05 Acyclic frag limit exceeded AD06 Comms line requested is not profibus ADO07 Resource alloc failure 08 PMC not initialised 09 No more Cyclic data space ADOA No more cyclic tag space ADOB Attempt to append while running ADOC Data attribs not set ADOD Data group size type mismatch ADOE Data group size type unknown ADOF Data group wrong line number AD10 Data group node addr wrong AD11 Data group addresses not contiguou
159. r Full hardware and software status indication allows rapid verification and diagnostics DIAGNOSTICS Automatic health checks self testing and initialisation on power up FRONT PANEL ANNUNCIATION Front panel LEDs are provided for communications and processor status Control switches are also fitted on each processor module CONTINUOUS HEALTH MONITORING Extensive on going diagnostics and health monitoring of communications and I O status Chapter 1 028225 1 2 Issue 2 Nov 03 PROCESS SUPERVISER HANDBOOK 1 3 2 FEATURES Cont WATCHDOG Watchdog relay for each processor with Connect module front panel AND OR connections yo Distributed I O is networked using serial communications links CONFIGURATION Strategies and sequences configured downloaded monitored with Eurotherm Project Studio or the resident configura tor needs external terminal BLOCK STRUCTURE Continuous strategies are built up by interconnection of fixed function blocks from a comprehensive library of ana logue and logic elements common to all LIN based instruments ST USER ALGORITHMS Special ACTION blocks support user algorithms written in ST Structured Text and are well suited to implement plant logical devices BLOCK SUPPORT All standard LIN data base function blocks are supported in redundant mode Special diagnostic blocks are available for hardware and software status reporting ENCLOSURES Process supervisor units ca
160. r the right hand pair for the right hand processor Note System B connectors not supported at time of print Connection with an ELIN hub is made using a RJ45 to RJ45 cable assembly When connecting to the ELIN Hub a straight through cable is used When connecting directly a cross over cable is required Fig 2 5 1 shows the con nections erate A ee To 1 NONE p 1 Tx 2 Orange 2 White green om 3 Blue i 4mm o eom 4 1 1 i 1 Orange Ld i White green i i In ae eee BS PH H EN i t i Green i 1 White Brown l ter ad a m Brown or 1 sf a Straight through version i i i vt i t i 4 i ie eto ts View on rear of connectors Hi e Straight through cable SHROUD SCREEN 2 Orange emm 3 White green 3 Blue 4 Blue white 7 0mm 5 6 Gack Omm 6 7 White Brown See 7 1 1 i 1 m Orange e E i Blue NE MESE M Bluewhite 000000000 ie i i Green 1 1 White Brown Pop i ME b Cross over version
161. r 2 S can not see the primary and reports Faulty network LED flashes red Units desynchronise with processor 1 remaining the primary Processor Processor 1 2 P primary S secondary Processor 1 initially primary processor 2 initially secondary Figure 4 8 2a Break point locations Table 4 8 2a Processor reaction to figure 4 8 2a cable breaks Break 2 poe Processor reaction Break 1 Processor 1 P can see no slaves and reports Faulty network I OB LED flashes red Pro unit 1 VO unit 2 cessor 2 S can see the primary and reports OK LED steady green Units remain unit unit synchronised Break 2 Processor 1 P can see some slaves and reports faulty slave LED flashes green Processor X Break 1 2 S can see the primary and reports OK LED steady green Units remain synchronised Biden Break 3 If processor 1 is the primary Processor 1 P can see all slaves and reports OK LED steady green Processor 2 S cannot see the primary and reports Faulty network LED flashes red Units desynchronise with processor 1 remaining the primary If processor 2 is the primary processor 2 P can see no slaves and processor 1 S cannot see the primary Both report faulty network LEDs flash red Processors change over Processor 1 P now sees all slaves and reports OK LED steady green Processor 2 S cannot see Pro cessor 1 P and reports Faul
162. r is not communicating over the LIN because the cable is damaged or disconnected or there is a hardware electronics failure An interconnection failure causes the relevant comms LEDs associated with the affected processor module to flash on and off A hardware fault is indicated by the relevant System or i o LED s being illuminated continuously red A LIN failure in a synchronised primary processor module causes primary secondary changeover and loss of synchro nisation i e Primary synch adopts Secondary unsynch and Secondary synch adopts Primary unsynch Figure 6 2 2 shows that if an unsynchronised primary processor module suffers a LIN failure no changes of state oc cur there are no arrows leading out of the PRIMARY UNSYNCH box In the event of a LIN failure in a synchronised secondary processor it adopts the Secondary unsynch state yellow standby LED off and the primary processor module correspondingly desynchronises to the Primary unsynch state If the secondary processor module was unsynchronised at the time of the failure no change of state occurs EFFECT OF LIN FAILURE ON REDUNDANCY MODE CONTROL LIN failure affects the ability to synchronise processor modules A LIN failed secondary processor cannot success fully be synchronised with the primary by pressing the primary s synch switch for example Attempts to do this are inhibited by the redundancy control software and this is indicated by the yellow standby LED s lack of re
163. re abs eat es ethers 1 1 1 2 OTHER INFORMATION SOURCES 1 1 1 3 THE PROCESS SUPERVISOR UNITS 1 1 1 371 Typical applications ERR He ere Ie sevens 1 2 T 3 2 Fedt res 22 425 c ee ete Ro RED nde 1 2 toot ett en oto sert bue at tote at entes 1 2 MODBUS eet b 1 2 PROFIBUS eu p 1 2 REDUNDANT PROCESSOR MODULES 1 2 AUTOMATIC TAKE OVER 1 2 REDUNDANT POWER SUPPLY CONNECTION 1 2 LIVE PROCESSOR REPLACEMENT 2 2 1 2 DIAGNOSTICS her ace erecto ead 1 2 FRONT PANEL ANNUNCIATION esee 1 2 CONTINUOUS HEALTH 1 2 WATCHDOG 2 rts suce dag d PO rere ERI d a resta uci 1 3 Pom ETE 1 3 CONFIGURATION trente 1 3 BLOCK STRUCTURE tease Haste ee E Eo EE ED Ee NER EO ORAE EUR 1 3 ST USER ALGORITHMS deae nate th ertet e eene 1 3 BLOCK SUPPORT oett eee tota bete tree ed tee eto etd es etia 1 3 ENCLOSURE S T 1 3 CHAPTER 2 INSTALLATION 2 1 2 1 SAFETY AND EMC INFORMATION eee 2 1 2 1 1 Installation requirements for 2 1 2 1 2 Installation safety requirements
164. red Master mode only This sets the maximum number of registers register table or bits digital table that can be read or written in a single Modbus transmission Scan count defaults to the same value as Count i e as the table size which results in the whole table being updated each polling cycle If Scan count is made less than Count for a particular table it takes more than one cycle to be updated but the overall polling cycle speeds up This may be required for Modbus devices with limited buffer sizes Master mode only This specifies the hexadecimal slave number value of the instrument on the Modbus network in which the data registers or bits associated with this master table are located TABLE MENUS A table menu is accessed from the tables list by highlighting the required table number in the first column headed Table and pressing Enter To highlight fields you can move the arrow cursor around a table menu using the mouse or the PC s Home End and cursor keys Table menus allow the mapping between the LIN database fields and the Modbus addresses to be configured Figure 5 6 3b shows the default table menu for a register or diagnostic table Note that table headings differ for register and digital tables but that some fields are common to both Field DB Write and MOD Write Register Field DP Format DB Write MOD Write Value 0 0 Normal Enable Enable 20000 1 0
165. reset CPU in reset Power up sequence in progress Duplex Redundancy communications valid System in non redundant mode Inter CPU communications failed Table 6 2 1 Processor LED functions HAO28225 Issue 2 Nov 03 Chapter 6 Page 6 3 PROCESS SUPERVISOR HANDBOOK 6 2 2 Processor failure modes The front panel LEDs can indicate directly the following processor module failure or potential failure modes power loss watchdog failure desynchronisation loss of primary status database halt communications failure and ICM failure When a processor which is running as one of a redundant pair fails it usually changes its redundancy state in re sponse to the failure e g from primary to secondary or from synchronised to unsynchronised Figure 6 2 2 maps out various ways in which a pair of processor modules might fail and shows how they change redundancy state as a con sequence In the figure the boxes represent possible processor module states and the arrowed lines between boxes represent transitions from one state to another Arrows are labelled with the fault conditions causing the transition Primary processor module and secondary processor module are abbreviated as 1 and 2 respectively The front panel LEDs help to identify what state each processor is in as well as the nature of any failure The Comms LEDs will be on off or flashing as indicated in table 6 2 1 ci eg kas IE FER
166. ry 2 DN261448 Chassis fan assembly on processor module lower panel sess LA260259 Filter for chassis fan assembly sessssssessseeeeeeren eene BH240476 Capacitor board excluding AH028035 Capacitor board fan for cooling CPU sese LA028125 Power supply Input mains Output 24Vdc at 2 5 2500P 2A5 Power supply Input mains Output 24Vdc at 5 A max sese 2500P 5A0 Power supply Input mains Output 24Vdc at 10 A max see 2500P 10A External AV nei ee hee ele bete hal atten 89537 Charger for external battery Supply voltage 24 4 89538 24V Communications Isolator EIA232 EIA232 sess To be issued later ALIN Cables 1x RJ45 connector and ferrules for screw terminals S 9508 5 1RJ45 xxx RJ45 connectors both ends 2 n nene e eet S 9508 5 2RJ45 xxx Ferr les 59508 5 2 connector one end RJ45 connector at other S9508 5 RJ11 45 xxx Cable without termination ee ces S9508 5 xxx xxx cable length in 10 cm increments to
167. s AD12 Not in assembling mode AD13 Cyclics not configured AD14 Cyclics not running AD15 Attempt to change card state AD16 Bad data group list AD17 Changeover not complete AD18 Acyclics not ready AD19 Too many diag clients Line already initialised AD1B Comms attribs ptr failure ADIC Comms attribs data failure AD1D Cannot achieve cycle time ADIE Master baud rate not supported ADIF Cannot kill cards DB AD20 AD21 AD22 AD23 AD24 AD25 AD26 AD27 AD28 AD29 AD2A AD2B AD2C AD2D AD2E AD2F AD30 AD31 AD32 AD33 AD34 AD35 AD36 AD37 AD38 AD39 AD3A AD3B AD3C AD3D AD3E Not used Unable to set master protocol params Unable to set master comms params Unable to set slave comms params Failed to start profibus line task Failed to stop profibus line task Bad slave diagnostic Acyclics restarted Master rejected acyclic req Master acyclic resp error Slave acyclic req rejected Slave acyclic resp error Acyclic timeout No slave acyclic resp Failed to get diags Failed to get slave diags No slave diags available Bad pointer parameter Parameter out of range Slave cfg overflow Slave prm overflow acyclic data too big C2 acyclic data too big Slave not running Pending acyclic C2 RW not supported by slave C2 unexpected connection close Master card startup error Not used Could not get slave IO data Slave not running at changeover Table 6 6 2y Profibus error codes 9Dxx
168. s are increased to workable values Note Many block types have execution times which vary according to operating parameter values and dy namic changes to LIN loading for example increasing numbers of remote instruments starting to cache blocks within the local instrument Such factors can reduce the accuracy of the original estimates 7 3 2 Automatic dynamic tuning To compensate for the variable nature of user task execution times the spread of CPU loading across user tasks and system tasks is monitored and user task repeat rates are altered dynamically to ensure a fair spread of CPU allocation This dynamic tuning is adequate for most applications but where task repeat timing is critical the TaskRptN values in the Process Supervisor block can be adjusted to achieve optimum performance Dynamic tuning attempts to adjust user task repeat rates to allow the Bgnd task to complete one database scan typically every 2 seconds but never less often than once every 4 seconds 7 3 3 Manual tuning The USERTASK block allows execution times and repeat times for all the user tasks and the cached block server to be monitored The PS TASK block shows the percentage CPU usage by the various user and system tasks in the instru ment The prioritised nature of the user tasks should be allowed for when adjusting repeat rates 1 is the highest prior ity 4 the lowest The reported execution time for a user task may include a period of suspension wh
169. s failUre tei etre edet e ice t bee e E s 6 7 6 3 POMER UP FAILURE e pO erue t 6 7 6 3 1 Processor unit power up routine 6 7 6 4 POSTS POWER ON SELF TESTS 2 2 6 10 ERROR TYPES bet 6 12 6 5 DIAGNOSTIC BLOCKS eiie etc ER T ENS NUUS 6 12 6 6 ERROR NUMBERS o E eR ere RE DIRE 6 13 6 6 1 Error number structure J eee t wr ORA E re 6 13 RUNNING PACKAGES eiit Io tert et ete e tovt 6 13 DGA Error messages oet ert EH EEUU HIN Me tse 6 13 Cont Section i 028225 Page 6 Issue 04 PROCESSS SUPERVISOR HANDBOOK LIST OF CONTENTS Section Page CHAPTER 7 TASK ORGANISATION amp TUNING 7 1 712 ito te terere 7 1 LY ASRS hh ee TIE E 7 1 122 age 7 1 19 WTask EUFCHODS he 7 1 7 1 NES TASK 25 ee eren ee e te ERN ET ER QU dos 7 1 USER TASKS I vIQUA ck este scons ERE ARE REN IN 7 1 GACHE SYNC SERVERS n e rer eere Er ete te M eo 7 1 CACHE CONN SERVER s ceret eon ER rS E PEU 7 1 5
170. ser to configure communications ports exercise the LEDs re format the user disk etc from the terminal It is also possible to initiate a full Power on Self Test POST from the M Monitor Whilst the M Monitor is in use the watchdog LED is illumi nated continuously green but the relay remains in its alarm state To exit from the M Monitor Quit 0 is used and the system continues with Start up Note for more details refer to Chapter 8 Service Chapter 4 028225 4 10 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 4 7 START UP WITH SERVER STALL The use of the Server Stall option of the config block slows the data base start and synchronisation because it forces a complete read of all DCM block read fields for the lines on which it is applied This takes typically 12 seconds per I O controller slave node For details of the Server Stall option please refer to the Instrument s Configuration block section in Chapter 10 of the Linblocks Reference Manual HA082375U003 4 8 REDUNDANT MODE WORKING 4 8 1 Redundancy decisions When the units are acting as a duplex redundant pair the primary and secondary units will independently derive a comms status and for ELIN ALIN and Profibus protocols each unit will derive an error weight see table below Normal redundant operation will take place only if the primary processor believes that both processors have an equal view of the LIN Profibus networks
171. sk connections are then executed in order All connections sourced from this user task are now copied into their destination blocks in all higher priority user tasks as a single indivisible operation 5 The task busy flag is removed Notes 1 This structure results in the least work being carried out by the highest priority task 2 Tasks may be suspended under the control of the strategy via the Process Supervisor block s UsrTaskn parameters thereby allowing them to be event driven Connections Connections Mark task Input connects e lo Output con as Busy from higher nects to higher priority tasks Execute blocks priority tasks Mark task as Unbusy Coherent task body Figure 7 2 2b User task server operation Chapter 7 HA028225 Page7 4 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 7 3 USER TASK TUNING 7 3 1 Repeat times amp execution times The Process Supervisor block s parameters TaskRpt to TaskRpt4 allow the minimum repeat time for each user task to be specified When set to zero the minimum repeat time is as short as possible At database startup the execution time of each user task is estimated and these estimated times are compared with the requested TaskRptNs An estimated percentage of total CPU power required for each task is then derived If the re quired CPU power exceeds what is available the user task minimum repeat time
172. sponse Chapter 6 028225 6 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 2 7 Database stop If the database in the primary processor stops running for any reason the green primary LED starts to flash and the processor modules desynchronise Attempts to resynchronise are inhibited by the redundancy control software The yellow standby LED of the secondary processor is extinguished 6 2 8 I O Comms failure This occurs if a processor detects a hardware or interconnection fault in the link to the I O system s it is attempting to communicate with If a fault is detected this is indicated by the relevant i oA i oB or System LED s going red ei ther continuous red hardware fault or flashing red off connection fault As shown in figure 6 2 2 if an I O failure is detected with redundant processors in any state other than unsync the two processors will go into their unsync states If the failure is in the primary then the secondary will become the new primary and assume control and the original primary will become the secondary If the failure is in the second ary no change over occurs 6 3 POWER UP FAILURE 6 3 1 Processor unit power up routine A number of error conditions can occur during the power up phase of a processor module This power up routine is described in Chapter 4 and this should be referred to for detailed information Various messages are generated by the processor module during power up and th
173. ss by other personnel is not recommended S MONITOR ACCESS The S Monitor is accessed by typing 6 from the M Monitor main menu described in section 8 4 1 above sx Reo Main menu level 0 0 Quit 1 Help 2 Display basic machine status 3 Display extended machine status 4 5 6 7 Diagnostic menu emory status Show boot info Date Time set T Selection _ QUIT Selecting 0 in this menu quits the S monitor If the watchdog retry enable switch is set on section 2 3 5 above the unit will re start If the switch is set off the unit must be reset manually or powered off then back on again HELP To be issued later Section 8 028225 8 16 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 8 S MONITOR Cont DISPLAY BASIC MACHINE STATUS Accessed by typing lt 2 gt from the main menu this page displays the following information lt Display gt Y y N n Y lt CR gt RTC power gt Ok Real time clock lost power CMOS checksum gt Ok CMOS checksum is bad Memory compare gt Ok Memory size compare error CMOS time gt Ok CMOS time invalid lt Display gt Y y N n N lt CR gt sx Wd Main menu level 0 etc DISPLAY EXTENDED MACHINE STATUS Accessed by typing 3 from the main menu this page displays the following information lt Display gt Y y N n Y lt CR gt Register 0 0 Reason
174. ss is complete after which the LED stops flashing and is illuminated continuously green 4 3 3 Watchdog relay For primary or simplex units the watchdog relay is in its alarm state until the Primary LED is continuously illumi nated For secondary units the watchdog relay comes out of alarm when the database is started part way through the synchronisation sequence Chapter 4 HA028225 Page 4 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 4 4 STARTING UP A PAIR OF PROCESSORS 4 4 1 Redundant mode This start up sequence is similar to that described for a single processor section 4 3 above except in the control and action of the Standby and Duplex LEDs Figure 4 3 1 above shows the locations of the various LEDs Powering up decisions Figure 4 4 1 shows the states possible with a pair of processor units in redundant mode Off St ie 1 tarting unsynch LEDs Power Watchdog LEDs Power Watchdog Comms Primary Comms Primary Secondary 3 Synching Synching Primary econaary synch synch LEDs Power Watchdog LEDs Power Watchdog Primary Comms Standby Comms Figure 4 4 1 Power up redundancy states for a pair of processor units in redundant mode PRIMARY SECONDARY CRITERIA With processor units in redundant mode it is necessary that one be defined as the primary the other as the secondary As described above in section 4 1 of this chapter the primary unit initially as
175. start Cannot stop Empty database Configurator in use or device busy DBF file write failed More than one RUN file found RUN file not found Connection Source is not an O P Multiple connection to same I P Connection Destination not I P No free connection resources Bad conn src dest block field Invalid connection destination Warmstart switch is disabled No database was running Real time clock is not running Root block clock is not running Coldstart time was exceeded Root block is invalid Too many control loops Coldstart switch is disabled Unsynchronised Block Types DB Filing system mismatch Unsynchronised Secondary Operation forbidden whilst CPUs synchronising changing over Pwr up data inhibits run POST hardware failure Not fixed function strategy Default strategy missing Table 6 6 2b Database system error codes 83xx Chapter 6 Page 6 14 HAO28225 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 6 2 ERROR MESSAGES Cont 8501 8502 Out of FRAM DO NOT save file Out of N RAM DO NOT save file Table 6 6 2c Objects system error codes 85 8602 8603 8611 8613 8614 8615 8616 8617 8619 861A Bad channel number Bad type code Bad handle or not hist File exists Exceeded global limit Unexpected end of file Read error Write error Bad filename Bad timestamp Table 6 6 2d Trend system error codes 86xx 8701 8702 8703 8704 8705 8706 8707 8708
176. start up but can be forced by operation of the primary sync push switch 3 5 3 5 changeover switch Operation of the primary processor s sync changeover switch causes the secondary module to start synchronising with the primary module The secondary s Standby LED flashes during this synchronising process Once synchro nisation is complete operation of the secondary processor s sync switch causes primary secondary changeover 3 5 4 Desync switch Operation of the desync push switch causes synchronised processors to de synchronise Chapter 3 028225 Page 3 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 3 5 5 Processor module Synchronisation Applicable only to redundant systems synchronisation means the bulk transfer of all relevant data from that processor which is designated the primary processor to that which is designated the secondary followed by continuous mainte nance of this copied data This allows the secondary processor to take over from the primary should the primary fail This synchronisation process takes place automatically if both processor modules are powered up together and have previously been run as a redundant synchronous pair Should either of the above conditions not be met then at power up the primary and secondary processors adopt unsynchronised states Primary unsynch and Secondary unsynch In such a case the secondary module cannot take over from the primary in the event of failur
177. sumes control and the secondary tracks the primary such that it can assume control should the primary unit fail Which of the processors powers up as the primary is determined as follows 1 If both processors are powered up simultaneously from their as delivered default states the left hand PROCES SOR MODULE as viewed from the front attempts to assume primary status 2 If both processors are powered up simultaneously from other than default state further tests must be made on the basis of last time s information held in battery backed memory This information contains data relating to whether this processor was primary or secondary prior to the last power off If both processors were primary or both secondary last time or if the data is inconclusive then the left hand processor will attempt to assume pri mary status this time otherwise they will power up according to last time s status 3 If the processors are powered up sequentially then the first powered will attempt to assume primary status HA028225 Chapter 4 Issue 2 Nov 03 Page 4 7 PROCESS SUPERVISOR HANDBOOK 4 4 1 REDUNDANT MODE Cont AUTOSYNCHRONISATION Once the primary secondary status of the processors has been determined the system must decide whether synchroni sation of the primary and secondary should be automatic or whether it should proceed only after a request from the operator sync switch This decision is made as follows If the pro
178. ted 8D11 Bad Number Table 6 6 2n MODBUS error codes 9Axx 9 01 Illegal unique task id Table 6 6 2i Structured text error codes 8Dxx 9 02 Task id already being used 9B03 No more task control blocks 8F01 PCLIN Card not responding 9B04 Out of XEC memory 8F02 PCLIN Request failed 8 04 EDB not known or not external 9B64 Task aborted 8 07 Unknown EDB 9 65 Task timeout 8FOA Unable to delete ED 8 14 block number 8F15 Template mismatch 8F16 Block failed to attach 8F17 Block failed to detach Table 6 6 2 PCLIN PC I F package error codes 8Fxx Table 6 6 2p error codes 9Bxx 9001 Invalid PIN 9002 PINs do not match unchanged 9003 Invalid PIN reset to 1234 9004 Access denied 9005 Invalid default security info 9006 Invalid DTU A security info 9007 Invalid DTU B security info Table 6 6 2k T1000 menu system error codes 90xx 9100 Couldn t open config file 9101 Section not found 9102 Parameter not found 9103 Argument not found 9104 Config area too small 9105 Config file syntax error 9106 Config header corrupted 9107 Nota number 9108 Out of memory Table 6 6 21 Configuration files error codes 9 1xx Chapter 6 028225 6 16 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 6 2 ERROR MESSAGES Cont 9 01 Already registered A001 Could not create user s event MAL 9 02 Too many kernel users A002 Could not open user s event MA
179. ted and the unit continues its start up procedure 8 4 3 Help To be issued later 028225 Section 8 Issue 2 Nov Page 8 7 PROCESS SUPERVISOR HANDBOOK 8 4 4 Display saved system features This screen is accessed by typing 2 then or y in response to the Display enquiry Typing N or n returns to the main menu The display lists the current settings for the communications ports associated with this processor unit Sys Ethernet gt Single I O Chan gt Single I O chan A configuration gt ArcNet I O chan configuration gt Profibus EXP chan A configuration gt Serial EXP chan configuration gt Serial Sys Ethernet Displays either Single or Redundant as appropriate for the internal system communications I O Chan A Displays either Single or Redundant chan A configuration Currently always set to ArcNet ALIN chan configuration Either none or Serial Modbus or Profibus EXP chan A configuration Either none or Serial Modbus or Profibus EXP chan B configuration Either none or Serial Modbus or Profibus To return to the main menu type N or n in response to the Display enquiry 8 4 5 Diagnostics menu The diagnostics menu is accessed by typing 3 in the main menu The menu allows a number of checks to be carried out as detailed below Note These checks can affect the machine s ability to restart and should be
180. tential Section 9 Page 9 2 028255 Issue 04 PROCESS SUPERVISOR HANDBOOK 9 1 3 Connect module specification ALIN ports Connectors Network medium Network type Speed of nodes Line length max Parallel wired pairs of shielded RJ45 connectors per processor unit ArcNet screened twisted pair 100 Ohm Token bus 2 5 Mbits sec 8 extendable by repeater 100 metres extendable by repeater Isolation 50Vdc 30V ac 5 6kQ to OV ELIN ports Connectors Pairs of shielded RJ45 connectors per processor unit Network medium Protocols Speed Network Topology Line length max Allocation of IP address Isolation Ethernet Cat5 LIN over Ethernet IP ELIN Modbus TCP RTU slave FTP 10 100TX Star connection to a hub 100 metres extendable by repeater Manual Link Local or BootP 50V dc 30V ac Modbusg J bus EIA422 485 Connectors Protocol Data rate Data format MODBUS data tables Table length max Memory allocated to tables Isolation Parallel wired pairs of shielded RJ45 connectors per processor unit MODBUS JBUS RTU slave Selectable between 600 and 38 400 Baud 8 bits 1 or 2 stop bits selectable parity 16 configurable as registers or bits 200 registers or 999 bits 6000 bytes 50Vdc 30V Modbus DCM Connectors Protocol Data rate Data format Parallel wired pairs of shielded RJ45 connectors per processor unit MODBUS
181. th its Primary LED flashing on and off and the relevant Comms LED in its fault condition Note Checks are not carried out on Modbus The System now attempts to start the software determining first whether the options switch SW2 on the backplane is set for redundant or non redundant mode If redundant working is required the primary secondary status of each processor module is decided according to the criteria in Section 4 4 1 if necessary using signature data relating to last time s power down auto synchronise states and so on A check is made to ensure that the ICM inter processor communications are valid and if so the primary processor continues its power up sequence according to the mode selected at the front panel switch The STANDBY LED starts flashing on and off when the primary starts to down load data to the secondary If the ICM test fails or if non redundant working is required the processor s continue the power up sequence ac cording to the mode selected at the front panel switch A diagnostic test result code appears at the bottom of the screen with a value of 0000 check successfully completed 0001 only minor problems reported or 0002 major problem s reported If the code is 0002 the processor fails to power up 028225 Chapter 6 Issue 2 Nov Page 6 11 PROCESS SUPERVISOR HANDBOOK 6 4 POWER ON SELF TESTS Cont ERROR TYPES SERIOUS ERRORS Serious errors are reporte
182. tion database mapping see TABLE MENUS below Figure 5 6 3a shows an example tables list with Table 1 configured as a register table The first four columns Ta ble Type Offset and Count are common to both the slave and master modes of operation The remaining three Functions Scan count and Slave No appear only in master mode configuration not shown in the figure Table Type Offset Count Table Offset Count Register gt Unused Unused Unused Unused Unused Unused Unused nused Unused Unused Unused Unused Unused Unused CO FL OU WANA 015 WN FP C OO QOO OO OO Oe OY Q9 6 OOD CX gt Oe Or O69 C OOo ie Unused Figure 5 6 3a Modbus tables list slave mode Table number non editable The table menu described below for any table is accessed by highlighting the table number field and pressing Enter This field which defaults to Unused lets you create a new table or change the type of an existing table Enter a Type field select a type and press Enter Other fields in the tables list associated with your selection automatically adopt default values The Type options are Unused The table is deleted Register Maps LIN database parameters onto standard 16 bit Modbus registers Digital Maps LIN digital boolean or alarm values onto bits in the Modbus address space Diagn
183. tion if the source block is unchanging as can easily happen particularly if all block fields are digital values then the connections are not continually re evaluated This allows other tasks to write to the connection destination leaving the source and destination of the connection with different values You should ensure that your strategy does not write to connection destinations 5 5 2 COPY Creates duplicates of existing blocks Select COPY from the main menu to display all the blocks in the control strat egy in semi graphical format as shown in Figure 5 5 2 The blocks are displayed from left to right in order of crea tion Move the cursor gt to a block and press lt Enter gt The block is duplicated and added to the strategy and its Overview page automatically appears ready for parameterising The duplicate retains all the original parameter values except for the Block field which has the default tagname NoName Input connections not copied nor are I O block site numbers COPY Select block ee gt T100 SIM_1 TIC_100 PID_1 FIC_101 Se a ee Figure 5 5 2 COPY display example Pressing Escape returns the COPY display where the copied block can be seen added to the list Press Escape again to return to the top level menu 5 5 3 DELETE Deletes blocks from the control strategy Select DELETE from the main menu to display all the blocks in the control strategy in the
184. tp www eurotherm com au Austria Eurotherm GmbH GeiereckstraBe 18 1 A1110 Wien Telephone 43 1 798 76 01 Fax 43 1 798 76 05 e mail eurotherm eurotherm at http www eurotherm at Belgium and Luxemburg Eurotherm S A N V Rue du Val Notre Dame 384 4520 Moha Huy Belgium Telephone 32 0 85 274080 Fax 32 0 85 274081 e mail sales eurotherm belgium be http www eurotherm nl Denmark Eurotherm Danmark A S Finsensvej 86 DK 2000 Fredriksberg Telephone 45 38 871622 Fax 45 38 872124 e mail salesdk eurotherm se Finland Eurotherm Finland Aurakatu 12A FIN 20100 Turku Telephone 358 2 25 06 030 Fax 358 2 25 03 201 France Eurotherm Automation Division Chessell Parc d Affaires 6 Chemin des Joncs BP55 F 69574 Dardilly CEDEX Telephone 33 0 4 78 66 55 20 Fax 33 0 4 78 66 55 35 e mail chessell automation eurotherm co uk http www eurotherm tm fr Germany Eurotherm Deutschland GmbH OttostraBe 1 65549 Limburg Tel 49 0 64 31 2 98 0 Fax 49 0 64 31 2 98 119 e mail info regler eurotherm co uk http www eurotherm deutschland de Great Britain Eurotherm Limited Faraday Close Worthing West Sussex BN13 3PL Telephone 44 0 1903 695888 Fax 44 0 1903 695666 e mail Sales recorders eurotherm co uk or Support recorders eurotherm co uk http www eurotherm co uk Hong Kong Eurotherm Limited Unit D 18 F Gee Chang Hong Centre 65 Wong Chuk Hang Road Aberdeen Telephone 852 28
185. ty network LED flashes red Units desynchronise with proces sor 1 the primary Processor Processor 1 2 P primary S secondary Processor 1 initially primary processor 2 initially secondary Figure 4 8 2b Alternative cabling Table 4 8 2b Processor reaction to figure 4 8 2b cable breaks Notes Terminators should be used at each end of the cable run no matter what cabling scheme is used 2 Ifanon cable network fault ocurs e g power loss to i o units then the Primry will see no slaves and report faulty network I OB LED flashes red The secondary can see the primary and so reports LED steady green Units remain synchronised Chapter 4 HA028225 Page 4 12 Issue 2 Nov 03 PROCESS SUPERVISO R HAN DBOOK CHAPTER 5 CONFIGURATION The main topics of this chapter are 5 1 Tools The Configurator and LINtools 5 2 Configurable items 5 3 Preparing to run the Configurator 5 4 Running the configurator 5 5 Database configuration 5 6 Configuring Communications Modbus only 5 1 TOOLS THE CONFIGURATOR AND LINTOOLS Most configuration will be done before despatch using the LINtools component of the Eurotherm Project Suite This chapter explains how databases and communications parameters are configured for the unit using the Configurator program resident within the processor unit s In redundant mode the program is resident only on the Primary proc essor
186. ummary BLOCK FUNCTION XX XXXX Block server tasks timing information in priority order ICM DIAG ICM Inter CPU Messaging for Redundancy diagnostics Statistics on numbers and types of mes sage passing between redundant processor modules RED CTRL Redundancy control block Shows Processor Redundancy Management Task PRMT parameters Can also be used to trigger processor module synchronisation desynchronisation and primary secondary processor swap FTQ DIAG Low level statistics on the queues maintained by the PRMT for interfacing with the various processes occurring in the Unit controller supervisor MDBDIAG Modbus diagnostics PMC DIAG Simple Profibus PBUS DIAG Detailed Profibus TOD DIAG Time of day synchronisation diagnostic block Statistics on broadcasts requests receipts rejections etc SFC DIAG Sequence related diagnostics and resource statistics Number of configured and available resources Chapter 6 028225 Page 6 12 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 6 6 ERROR NUMBERS This section lists the error messages that may be seen during the running of the Unit controller supervisor connected to a terminal either via the EIA232 port or over other serial ports 6 6 1 Error number structure All error conditions have an associated 4 digit number and usually a corresponding text message as well Error num bers are hexadecimal 4 digit groups The first two digits show the pa
187. un etre be dep itis 5 20 ModbUs 2 5 3029 REGERE BD 5 17 Configurator A Connection with 5 2 Address Running 5 3 Clashes 2 6 Configuring strategies 0 2 19 SWIM cess ae tenet ce ORNA atest ninn 2 5 CONFSpd 2 14 049900098 8 5 2 5 21 Alarms Connection module E A ct dt a 5 10 0 4 1 49 2 9 2 20 LEDES eSa ain onre ai enaena e a ar akie imti 3 4 Front 440940 4 8 2 9 du lieth M MAMMA 5 16 Specification 4 44 990200099 4 9 3 ate estan Oo tare mies hee 6 6 Connections 0 1 9 2 8 5 9 5 12 Failure sarme an 6 6 Types a database 5 11 set St 2 8 2 13 Control efficiency 5 2 loading 7 5 Non redundant system 1 0 5 2 ALIN connectors cecececcecececeecesescececestecereevececeeees 2 12 Redundant 4 7 4 1 5 2 r ka 5 1 5 15 4444 5 1 5 12 5 21 Automatic dynamic tuning 2 2222221 7 5 CPU Autosynchronisation 4 8 loading
188. up for the real time clock can be provided by an optional internal battery The int LED operates for this battery in the same way as described above for ext except in that the internal battery voltage must be greater than approximately 3 8V for the LED to be illuminated In order to achieve the minimum time duration specified above 24V power must have been applied to the processor module for 48 hours to ensure that the battery has been fully charged Note Recommended power supply and battery units are listed in chapter 9 of this manual 028225 Chapter 3 Issue 2 Nov 03 Page 3 3 PROCESS SUPERVISOR HANDBOOK 3 3 ALARM LEDS Alarms m m Figure 3 3 Alarm Relay LEDs This pair of LEDs is located near the top right of the processor module front panel and indicates the status of the relay outputs rll and 12 available at the 8 way terminal blocks on the Connect module Each LED illuminates yellow if its associated relay is in alarm state coil not energised This happens both in alarm and during start up Chapter 3 028225 3 4 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 3 4 COMMS LEDS Comms system O0 enm 00 ee Figure 3 4 Communications LEDs This group of eight LEDs is located just above the centre of the control panel 3 4 1 System i oA i oB These LEDs all operate in a similar way to one another to indicate th
189. used only to diagnose faults or to clear the memory Oe Quit 1 Automatic test sequence 2 PSE comm menu 3 Net menu 4 5 Profibus test Led Test eo Ss Selection _ Section 8 028225 8 8 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 5 DIAGNOSTICS MENU Cont AUTOMATIC TEST SEQUENCE Accessed by typing 1 in the diagnostics menu this carries out a number of tests and displays the results either as OK or ERROR before returning to the Diagnostics menu RTC contents check gt OK Expansion serial comm port 1 gt OK Expansion serial comm port 2 gt OK Sys ethernet port 1 gt OK DRAM 0 3 00000 bytes 66060288 bytes status gt OK I O ArcNet port 1 OK I O Profibus port 2 gt OK sius ias Selection _ PSE COMM TEST MENU Accessed by typing 2 this allows the Serial Communications to be checked This test requires that a three or five wire cable be connected between Expl and Exp2 ports with a cross over between Rx and Tx lines oit PSE Comm Test 0 1 Set 9600 Baud 2 Set 19200 Baud 3 Set 38400 Baud 4 Set 57600 Baud 5 Set Modbus Ch 1 to Master 6 Set Modbus Ch 2 to Master 7 Start loop test 3W 8 Start loop test 5W ee dere Selection _ Baud Rate Select required Baud rate for this test as required by typing 1 2 3 or 4 Baud rate is reset after the monitor is quitted
190. user configuration 028225 Section 8 Issue 2 Nov 03 Page 8 5 PROCESS SUPERVISOR HANDBOOK 8 3 PHYSICAL ARRANGEMENT INSIDE PROCESSOR MODULE Figure 8 3 shows the arrangement of circuit boards etc inside the processor module System Board lt Profibus Board 77 ARCNET Board CPU Board Capacitor Board User interface board Figure 8 3a Hardware organisation Section 8 028225 Page 8 6 Issue 2 Nov 03 PROCESS SUPERVISOR HANDBOOK 8 4 THE MONITOR Note The M monitor is intended as a diagnostic tool for Commissioning and or Service Engineers Access by other personnel is not recommended 8 4 1 Top level main menu access As described in chapter 4 above the start up process can be monitored at a suitable computer terminal connected to the Processor unit Config port During the start up sequence the message Press m key to stop auto start appears for one second or for 10 seconds if this is a TEST start Operation of the m key stops the start up sequence and calls the top level menu depicted below If the message is ignored the booting up process continues Press m key to stop auto start Main menu ases ad Level 0 0 Quit 1 Help 2 Display saved system features 3 Diagnostic tests 4 Manual set up 5 Automatic set up o S Monitor options E Selection 8 4 2 Quit Monitor is quit
191. wo processors defined initially as primary left hand processor and secondary right hand processor Setting the segment on left disables redun dancy mode and both processors if two are fitted run independently Notes Sequential Flow Chart programs cannot be run in redundant mode HA028225 Chapter 2 Issue 2 Nov 03 Page 2 7 PROCESS SUPERVISOR HANDBOOK 2 5 CONNECTIONS AND WIRING Units may be supplied mounted in an enclosure together with the appropriate termination assemblies either fitted in the enclosure or supplied in kit form Please refer to the documentation that was supplied with the enclosure for details of the connections and wiring If you are assembling the system yourself you should refer to the relevant Modules Reference Manual the LIN ALIN ELIN Installation amp User Guide HA082429U005 and the Communications Manual HA028014 for advice on connections and wiring to the I O modules Figure 2 5 below shows simplified overall connection diagrams for a control system using a an ALIN hub and b an ELIN hub Hubs are useful for individual line lengths of up to 100 metres For line lengths greater than this one or more pairs of hubs with fibre optic connections is recommended As detailed later in this chapter it is also possible with ALIN systems to connect local items together in series using a daisy chain technique rather than in a star lay out using a Hub
192. yellow at varying rates according to processor receive rx and transmit tx activ ity 028225 Chapter 3 Issue 2 Nov 03 Page 3 5 PROCESS SUPERVISOR HANDBOOK 3 5 CHANGEOVER LEDS AND SWITCHES The sync and desync switches are set behind the panel and should be operated when necessary by a blunt plastic tool such as the recessed end of a trim pot adjuster N primary standby sync changeover desync O Figure 3 5 Changeover LEDs and switches This group of components is located slightly below the centre of the processor front panel and is used to monitor and control the redundant non redundant mode selection The group consists of two LEDs Primary and Standby and two membrane switches sync and desync Section 3 5 5 below gives a brief description of synchronisation 3 5 1 Primary LED This LED is illuminated green if this processor module is currently the primary processor During start up this LED flashes on and off until a database has been loaded and is running successfully The LED is off if this processor is not the primary 3 5 2 Standby LED This LED is illuminated yellow continuously if this processor module is currently the secondary module of a synchro nised redundant system and is thus able to take over from the primary if required If this processor is the secondary the LED will flash whilst the processors are synchronising This normally happens during

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