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RS3t Service Manual Volume 2 August 1998 U.S. Manual PN: 10P56980202 A-4 Size Manual PN: 10P56980212 10P56986101 10P56986111 E 1987--1999 Fisher-Rosemount Systems, Inc. All rights reserved. Printed in the U.S.A. Components of the RS3 distributed process control system may be protected by U.S. patent Nos. 4,243,931; 4,370,257; 4,581,734. Other Patents Pending. RS3 is a mark of one of the Fisher-Rosemount group of companies. All other marks are property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products without notice. Fisher-Rosemount Systems, Inc. 8301 Cameron Road Austin, Texas 78754--3895 U.S.A. Telephone: FAX: (512) 835--2190 (512) 834--7313 Comment Form RS3t Manuals Service Manual 10P569802x2 Please give us your feedback to help improve this manual. Never Rarely Sometimes Usually Always D configuring making changes or enhancements ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ D operating the system ______ ______ ______ ______ ______ D troubleshooting D other __________________________ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ 1. Do you actually use this manual when you are: D 2. Does this manual answer your questions? 3. What could be changed in this manual to make it more useful? Errors and Problems: Please note errors or problems in this manual, including chapter and page number, if applicable; or send a marked-up copy of the affected page(s). May we contact you about your comments? j Yes j No Name ______________________________________________ Company ______________________________________________ Phone ______________________________________________ Date ______________________________________________ Fisher-Rosemount FAX #: (512) 834--7200 Thank you! Name Place stamp here Company Address Fisher-Rosemount Systems, Inc. Technical Documentation 8301 Cameron Road Austin, Texas 78754--3895 U.S.A. Seal with tape. SV: v RS3t Service Manual About This Manual The Service Manual provides information on service, calibration, maintenance, and troubleshooting RS3 hardware. The Service Manual provides a brief idea of the function of each device, along with details of cabling, LEDs, jumpers, and fuses. Installation planning data is covered in the Site Preparation and Installation Manual (SP). Devices are arranged in functional groups but the quickest way to find specific information is through the index. You can look a device up by name, part number, or the legend printed on the silkscreen. An abstract of the service data appears in the Service Quick Reference Guide (SQ), which is small enough to be readily portable. Factory Repair Items Parts of devices that are listed as replacement parts are permitted to be replaced in the field with the stated replacement part as designated in the user documentation. Any part of a device that is not listed as a replacement part is not to be replaced in the field, but must be returned to the factory for repair. Changes for This Release D D RS3: Service Manual Numerous corrections and minor revisions have been made throughout the manual. Information on the RS3 Millennium Package (RMP), the System Power Supply Unit, and the MPC5 Controller Processor with 4 Meg NV Memory has been incorporated into the manual. Information of the MAI16 and Loop Power Module has also been incorporated. About This Manual SV: vi Revision Level for This Manual The Service Manual is independent of the Software Release level. New equipment is added to the Service Manual with each release and older material is updated. You should always use the latest version of the Service Manual. Refer to This Document: For This Software Version: All Title Service Manual Date Part Number August 1998 10P569802x2 NOTE: The “x” in the part number is 0 for US size (8--1/2 x 11 inches) or 1 for A--4 size. References to Other Manuals References to other RS3 user manuals list the manual, chapter, and sometimes the section as shown below. Sample Entries: For ..., see CC: 3. Manual Title Chapter For ..., see CC: 1-1. Manual Title Chapter-Section Abbreviations of Manual Titles AL = Alarm Messages BA= ABC Batch CB= ControlBlock Configuration CC= Console Configuration DT = Disk and Tape Functions IO = I/O Block Configuration OP= Operator’s Guide OV= System Overview and Glossary PW= PeerWay Interfaces RB= Rosemount Basic Language RI = RNI Installation Guide RR= RNI Release Notes RP = RNI Programmer’s Reference Manual SP = Site Preparation and Installation SV = Service RS3: Service Manual About This Manual SV: vii Reference Documents Prerequisite Documents You should be familiar with the information in the following documents before using this manual: NOTE: The “x” in the part number is 0 for US size (8--1/2 x 11 inches) and 1 to 9 for A--4 size. System Overview Manual and Glossary Software Release Notes, Performance Series 1 1984-2640-21x0 10P56870106 Related Documents You may find the following documents helpful when using this manual: ABC Batch Software Manual 1984-2654-21x0 Alarm Messages Manual 1984-2657-19x1 ABC Batch Quick Reference Guide 1984-2818-1103 Configuration Quick Reference Guide 1984-2812-0808 Console Configuration Manual 1984-2643-21x0 ControlBlock Configuration Manual 1984-2646-21x0 I/O Block Configuration Manual 1984-2645-21x0 Operator’s Guide 1984-2647-19x1 PeerWay Interfaces Manual 1984-2650-21x0 Rosemount Basic Language Manual 1984-2653-21x0 RNI Programmer’s Reference Manual 1984-3356-03x1 RNI Installation Guide 1984-3357-02x5 RNI Release Notes 10P574830x1 Site Preparation and Installation Manual 10P569902x1 Service Quick Reference Guide 10P57000201 Software Discrepancies for Performance Series 1 10P56870304 User Manual Master Index RS3: Service Manual 1984-2641-21x0 About This Manual SV: viii RS3: Service Manual About This Manual Contents of Volume 1 Chapter 1: Power Section 1: AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 AC Entrance Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Feed AC Entrance Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Feed AC Entrance Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Feed AC Entrance Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 1-1-3 1-1-4 1-1-5 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1 AC/DC Power Supply (With Battery Backup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC/DC Power Supply (With Battery Backup) Alarm Contacts . . . . . . . . . . . . . AC/DC Power Supply (With Battery Backup) LEDs and Controls . . . . . . . . . . AC/DC Power Supply (With Battery Backup) Fuses . . . . . . . . . . . . . . . . . . . . . Battery Charger Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Card Jumpers and Test Points . . . . . . . . . . . . . . . . . . . . . . Battery Charger Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC/DC Power Supply (Without Battery Backup) . . . . . . . . . . . . . . . . . . . . . . . . . . . AC/DC Power Supply (Without Battery Backup) Measuring Output Current . AC/DC Power Supply (Without Battery Backup) Alarm Contacts . . . . . . . . . AC/DC Power Supply (Without Battery Backup) LEDs and Fuses . . . . . . . . . MTCC Remote Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTCC Remote Power Supply Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTCC Remote Power Supply Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Remote Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Remote Power Supply Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC/DC Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC/DC Unregulated Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC/DC Unregulated Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote I/O Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5503 for I/O Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5503 Remote Power Supply Connector Pin-Out . . . . . . . . . . . . . . . . . . 10P5503 Remote Power Supply LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5503 Remote Power Supply Checking and Adjusting Output . . . . . . . 10P5503 Remote Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Operator Interface Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5409 for Operator Interface Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5409 Remote Power Supply Connector Pin-Out . . . . . . . . . . . . . . . . . . 1-2-2 1-2-6 1-2-7 1-2-8 1-2-9 1-2-11 1-2-12 1-2-12 1-2-13 1-2-15 1-2-16 1-2-16 1-2-18 1-2-18 1-2-19 1-2-20 1-2-22 1-2-23 1-2-25 1-2-26 1-2-27 1-2-28 1-2-30 1-2-31 1-2-31 1-2-31 1-2-31 1-2-32 1-2-33 1-2-34 Section 2: RS3: Service Manual Contents SV: x 10P5409 Remote Power Supply LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5409 Remote Power Supply Checking and Adjusting Output . . . . . . . 10P5409 Remote Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5701 for Operator Interface Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P5756 for Operator Interface Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distribution Block Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-34 1-2-34 1-2-34 1-2-35 1-2-36 1-2-37 1-2-37 System Power Supply Units .............................. 1-3-1 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Cabinet and AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Cabinet DC Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a Housing in a Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a Power Supply in a Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Auxiliary AC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing a Power Supply Housing from a System Cabinet . . . . . . . . . . . Installing a Housing in a Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a Power Supply in a Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing a Power Supply from a Housing . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 1-3-3 1-3-5 1-3-6 1-3-7 1-3-7 1-3-8 1-3-11 1-3-12 1-3-13 1-3-13 1-3-13 1-3-14 1-3-15 1-3-16 1-3-16 1-3-16 1-3-18 1-3-18 1-3-19 1-3-20 1-3-21 1-3-21 DC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1 DC Power Distribution Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Output Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Output Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Distribution Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard DC Distribution Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant DC Power Distribution Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power Distribution System Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3 1-4-5 1-4-6 1-4-7 1-4-7 1-4-8 1-4-10 Section 5: Redundant Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1 Chapter 2: PeerWay Section 1: Electrical PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Twinax PeerWay Tap Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3 Section 3: Section 4: RS3: Service Manual Contents SV: xi Section 2: Section 3: Chapter 3: PeerWay Tap Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Tap Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding an Electrical PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twinax PeerWay Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twinax PeerWay Cable Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Twinaxial Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-6 2-1-6 2-1-7 2-1-9 2-1-11 2-1-12 Optical PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1 Optical Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Cables to an Optical Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Repeater/Attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Repeater/Attenuator Jumpers and LEDs . . . . . . . . . . . . . . . . . . . . . . . . Star Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding an Optical PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic Cable and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Fiber Optic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-3 2-2-5 2-2-6 2-2-8 2-2-8 2-2-9 2-2-10 2-2-13 2-2-13 Hybrid PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-1 PeerWay Extender (PX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PX System Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twinax Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drop Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding the PX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PX LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PX Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal/Test Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PX Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-2 2-3-5 2-3-6 2-3-6 2-3-6 2-3-7 2-3-7 2-3-7 2-3-8 2-3-8 2-3-8 2-3-9 Consoles Section 1: Multitube and Hardened Command Consoles and System Manager Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Multitube Command Console Keyboard Assemblies . . . . . . . . . . . . . . . . . . . . . . . . Multitube Command Console Keyboard Error Reporting . . . . . . . . . . . . . . . . . Configuration Keyboard and Enhanced Engineering Keyboard . . . . . . . . . . . Operator Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trackball Keyboard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Touchpad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 3-1-5 3-1-6 3-1-6 3-1-7 3-1-8 3-1-9 3-1-10 3-1-11 RS3: Service Manual Contents SV: xii Section 2: Section 3: Multitube Command Console Keyboard Electronics . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trackball Keyboard Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Touchpad Keyboard Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multitube Command Console Keyboard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . Password Keyboard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Keyswitch Keyboard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10P50840004 1984--3222--0004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--2889--0004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--1978--000x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Keyswitch Keyboard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--3222--1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--2889--1004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Interface Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Interface LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Interface Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Interface Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console CRTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS CRT: IIYAMA Vision Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multitube Command Console CRT: Hitachi HM--4721--D . . . . . . . . . . . . . . . . . Multitube Command Console CRT: ViewSonic 17GS . . . . . . . . . . . . . . . . . . . Multitube Command Console CRT: Mag Innovision . . . . . . . . . . . . . . . . . . . . . Multitube Command Console CRT: Sony . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multitube Command Console CRT: Conrac 7122 and 7241 . . . . . . . . . . . . . . . Conrac 7241 CRT Scan Board Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conrac 7241 CRT Scan Board Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . Conrac 7241 CRT Black Video or Black Bars on Screen . . . . . . . . . . . . . . Conrac 7241 CRT Power-up Diagnostics Failures . . . . . . . . . . . . . . . . . . . . Multitube Command Console CRT: Barco CD 551 and ICD 551 . . . . . . . . . . . . . . 3-1-17 3-1-18 3-1-19 3-1-20 3-1-20 3-1-22 3-1-23 3-1-24 3-1-24 3-1-25 3-1-26 3-1-26 3-1-26 3-1-26 3-1-27 3-1-27 3-1-30 3-1-32 3-1-33 3-1-34 3-1-34 3-1-35 Pedestal Command Console and Basic Command Console . 3-2-1 Pedestal Command Console Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Loop Callup Keyboard . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Command Entry Keyboard . . . . . . . . . . . . . . . . Pedestal Command Console Configuration Keyboard . . . . . . . . . . . . . . . . . . . Pedestal Command Console Trackball Keyboard . . . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Rotating (Alphanumeric) Keyboard . . . . . . . . . Pedestal Command Console Keyswitch Assembly . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Keyboard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Disk Interface Card (SCSI) . . . . . . . . . . . . . . . . . . . Remote Command Console Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedestal Command Console Printer Interface Card . . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 3-2-4 3-2-4 3-2-4 3-2-4 3-2-5 3-2-5 3-2-6 3-2-8 3-2-11 3-2-11 3-2-11 MiniConsole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 MiniConsole Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 RS3: Service Manual 3-1-12 3-1-12 3-1-13 3-1-13 3-1-14 3-1-15 3-1-16 Contents SV: xiii Section 4: Section 5: MiniConsole Power Regulator Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole PeerWay Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole OI Processor Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monochrome Video Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monochrome Video Generator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monochrome Video Generator Raster Test Button . . . . . . . . . . . . . . . . . . . . . . Monochrome Video Generator Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole Printer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole Floppy Interface (SCSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole Floppy Interface (SCSI) LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Disk Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Disk Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote MiniConsole Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-6 3-3-6 3-3-6 3-3-7 3-3-9 3-3-9 3-3-10 3-3-11 3-3-11 3-3-11 3-3-12 3-3-13 3-3-14 3-3-16 3-3-16 RS3 Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 RS3 Operator Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS CRTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS CRT: Hitachi HM--4721--D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS CRT: Iiyama Vision Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS Operator Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROS Operator Keyboard Interface Circuit Board (10P56910001) . . . . . . . ROS Operator Keyboard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethernet Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS3 Network Interface (RNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethernet Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TP/8 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FMS II Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FMS II Network Management Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transceiver Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uninterruptible Power Supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPS Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 3-4-3 3-4-3 3-4-3 3-4-4 3-4-6 3-4-7 3-4-8 3-4-9 3-4-11 3-4-11 3-4-12 3-4-13 3-4-13 3-4-14 3-4-14 3-4-15 3-4-16 3-4-17 Disk and Tape Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-1 Hard Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum QM32100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum Thunderbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBM Deskstar 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum ProDrive LPS 270S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum ProDrive LPS 170S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum ProDriver LPS 105S 3.5-Inch 102 Meg Hard Disk . . . . . . . . . . . . . . Quantum ProDriver 80S 3.5-Inch 100 MB Hard Disk . . . . . . . . . . . . . . . . . . . . Quantum ProDriver Q280 5.25-Inch 100 MB Hard Disk . . . . . . . . . . . . . . . . . . 3-5-2 3-5-5 3-5-6 3-5-7 3-5-8 3-5-9 3-5-10 3-5-11 3-5-13 RS3: Service Manual Contents SV: xiv Section 6: Section 7: Quantum ProDriver Q540 5.25-Inch 40 MB Hard Disk . . . . . . . . . . . . . . . . . . Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5-Inch Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25-Inch Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MiniConsole 5.25-Inch Floppy Disk Drive Jumpers . . . . . . . . . . . . . . . . . . . Magnetic Tape Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Tape Drive Cabling and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Tape Drive Jumper and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-15 3-5-16 3-5-16 3-5-18 3-5-20 3-5-23 3-5-24 3-5-25 Printers ................................................. 3-6-1 Fujitsu DL3800 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL3800 Printer Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL3800 Printer Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL4600 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL4600 Printer Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DL2600 Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer Vertical Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer Error Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fujitsu DPL24C Printer Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer Jumpers and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer Modification for 30.5 Cm Paper . . . . . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer Modification for Lowercase Printing . . . . . . . . . . . . . . . . . . . . . . TI 810 Printer Printing Half Page of Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-2 3-6-2 3-6-5 3-6-6 3-6-6 3-6-9 3-6-9 3-6-10 3-6-11 3-6-13 3-6-14 3-6-15 3-6-16 3-6-16 3-6-17 3-6-17 3-6-18 3-6-18 3-6-20 3-6-20 3-6-21 3-6-22 3-6-23 3-6-23 OI Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Electronics Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Manager Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Output Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Output Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Card Cage 10P52820001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Card Cage 1984--0660--0001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Interface LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Interface Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 3-7-4 3-7-5 3-7-5 3-7-7 3-7-10 3-7-14 3-7-15 3-7-17 3-7-18 3-7-20 RS3: Service Manual Contents SV: xv OI Power Supply LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Power Supply Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Power Supply Jumpers for a System Power Supply Unit . . . . . . . . . . . . . . OI Power Supply Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68040 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68040 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68040 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68020 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68020 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68020 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68000 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68000 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Processor 68000 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pixel Graphics Video Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pixel Graphics Video Generator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Character Graphics Video Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Character Graphics Video Generator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Character Graphics Video Generator Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Interface LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Interface Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCSI (Small Computer System Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCSI LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCSI Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--3301--000x SCSI Board 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984--1140--0001 OI SCSI Host Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Nonvolatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Bubble Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Bubble Memory LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Bubble Memory LED Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Bubble Memory Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV RAM LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV RAM LED Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV RAM Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV RAM Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS3: Service Manual 3-7-22 3-7-23 3-7-23 3-7-24 3-7-25 3-7-27 3-7-29 3-7-29 3-7-29 3-7-30 3-7-32 3-7-33 3-7-33 3-7-34 3-7-36 3-7-37 3-7-38 3-7-39 3-7-41 3-7-42 3-7-44 3-7-45 3-7-46 3-7-49 3-7-51 3-7-52 3-7-55 3-7-56 3-7-56 3-7-58 3-7-60 3-7-62 3-7-65 3-7-66 3-7-67 3-7-69 3-7-74 3-7-77 3-7-78 3-7-81 Contents SV: xvi Chapter 4: ControlFiles Section 1: ControlFile Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 ControlFile Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Data Bus Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Terminator II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Terminator Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 4-1-5 4-1-5 4-1-7 ControlFile Support Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1 PeerWay Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Buffer LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Buffer Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Buffer Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile 5 VDC Only Power Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile 5 VDC Only Power Regulator LEDs and Test Points . . . . . . . . . . ControlFile 5 VDC Only Power Regulator Jumpers . . . . . . . . . . . . . . . . . . . . . ControlFile 5 VDC Only Power Regulator Fuse . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Power Regulator 5 VDC and 12 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Power Regulator 5 VDC and 12 VDC LEDs and Test Points . . . . ControlFile Power Regulator 5 VDC and 12 VDC Jumpers . . . . . . . . . . . . . . . ControlFile Power Regulator 5 VDC and 12 VDC Fuses . . . . . . . . . . . . . . . . . Coordinator Processor (CP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP-IV Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP-I and CP-II Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP (Coordinator Processor) Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP LEDs, Test Points, and Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . CP LED Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP-IV+ (10P50870004 and 1984--4164--0004) . . . . . . . . . . . . . . . . . . . . . . . CP-IV (1984--4064--000x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP-II (1984--1594--000x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CP-I (1984--1448--0001 or 1984--1240--0001) . . . . . . . . . . . . . . . . . . . . . . . . CP Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NV (Nonvolatile) Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory LED Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM NV Memory Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NV Memory and Powering Down the ControlFile . . . . . . . . . . . . . . . . . . . . . . . Bubble NV Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bubble NV Memory: LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bubble NV Memory Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bubble NV Memory Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-2 4-2-4 4-2-5 4-2-6 4-2-7 4-2-9 4-2-11 4-2-12 4-2-13 4-2-16 4-2-18 4-2-19 4-2-20 4-2-21 4-2-24 4-2-27 4-2-29 4-2-31 4-2-34 4-2-34 4-2-35 4-2-36 4-2-37 4-2-38 4-2-39 4-2-41 4-2-44 4-2-46 4-2-48 4-2-49 4-2-49 4-2-49 4-2-50 4-2-52 4-2-53 4-2-53 Section 2: RS3: Service Manual Contents SV: xvii Section 3: Controller Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1 MPC (MultiPurpose Controller Processor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC II Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC I Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC5 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC II Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC I Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MLC (MultiLoop Controller Processor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MLC Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MLC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MLC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MLC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSC (Single Strategy Controller Processor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SSC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CC (Contact Controller Processor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CC Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX (Multiplexer Controller Processor) PLC (Programmable Logic Controller Processor) . . . . . . . . . . . . . . . . . . . . . . . . . . MUX and PLC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX and PLC Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Processor LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Processor LED Sequence on Power Up . . . . . . . . . . . . . . . . . . . . . MPC, CC, MUX, and PLC Controller Processor LEDs . . . . . . . . . . . . . . . . . . . MultiLoop and Single Strategy Controller Processor LEDs . . . . . . . . . . . . . . . Controller Processor Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Processor Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Processor Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2 4-3-5 4-3-7 4-3-10 4-3-12 4-3-12 4-3-15 4-3-18 4-3-19 4-3-20 4-3-21 4-3-24 4-3-24 4-3-24 4-3-25 4-3-26 4-3-26 4-3-27 4-3-28 4-3-29 4-3-29 RS3: Service Manual 4-3-30 4-3-30 4-3-31 4-3-32 4-3-32 4-3-33 4-3-35 4-3-36 4-3-37 4-3-39 Contents SV: xviii Contents of Volume 2 Chapter 5: Serial and Analog I/O Section 1: Analog Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1 Analog Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Card Cage Address Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card III / IV / V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card III / IV / V Communication Wiring . . . . . . Communications Connect Card III / IV / V Jumpers . . . . . . . . . . . . . . . . . . Communications Connect Card II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card II Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card (OBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Card Cage Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard . . . . . . . . . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard Jumpers . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard Fuses . . . . . . . . . . . . . . Smart Transmitter Daughterboard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter Daughterboard Installation . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2 5-1-3 5-1-4 5-1-6 5-1-7 5-1-8 5-1-10 5-1-10 5-1-13 5-1-16 5-1-17 5-1-18 5-1-21 5-1-21 5-1-22 5-1-23 5-1-24 5-1-28 5-1-30 5-1-31 5-1-34 5-1-35 5-1-36 5-1-37 5-1-37 5-1-37 5-1-38 5-1-40 5-1-41 5-1-43 5-1-44 5-1-45 5-1-46 5-1-51 5-1-52 5-1-53 RS3: Service Manual Contents SV: xix Section 2: Section 3: Section 4: Analog Extender Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Junction Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marshaling Panel Auxiliary Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-53 5-1-54 5-1-57 5-1-57 Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1 Contact Card Cage and Contact FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage FIC Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm FIC Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Jumpers . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Fuses . . . . . . . . . . . . . . . . . . . . Contact Termination Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Termination Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Termination Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Isolator Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Extender Card . . . . . . . . . . . . . . . . . . 5-2-2 5-2-4 5-2-5 5-2-6 5-2-7 5-2-8 5-2-8 5-2-10 5-2-12 5-2-13 5-2-14 5-2-15 5-2-16 5-2-17 5-2-19 5-2-20 5-2-22 5-2-23 5-2-25 5-2-26 5-2-27 5-2-28 Multiplexer FlexTerm Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-1 MUX FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Power Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Power Regulator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Communication Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Marshaling Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTD MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Front End Modules (FEMs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple and Voltage FEM and Universal Voltage FEM . . . . . . . . . . . . . 5-3-2 5-3-4 5-3-5 5-3-5 5-3-7 5-3-7 5-3-9 5-3-10 5-3-14 5-3-16 PLC (Programmable Logic Controller) Hardware . . . . . . . . . . . . 5-4-1 PLC FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC FlexTerm Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Controller Processor Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Port I/O Card Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-2 5-4-8 5-4-9 5-4-10 5-4-11 RS3: Service Manual Contents SV: xx Section 5: Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-232 Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-232 Port I/O Card RS-232 Pin Assignments . . . . . . . . . . . . . . RS-422/RS-232 Port I/O Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-232 Port I/O Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-232 Port I/O Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-422 Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-422 Port I/O Card RS-422 Pin Assignments . . . . . . . . . . . . . . RS-422/RS-422 Port I/O Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-422 Port I/O Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422/RS-422 Port I/O Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-13 5-4-13 5-4-15 5-4-16 5-4-17 5-4-19 5-4-20 5-4-22 5-4-22 5-4-23 5-4-24 MultiLoop and Single-Strategy FlexTerm Hardware . . . . . . . . . 5-5-1 MultiLoop FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-Strategy FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-Strategy FlexTerm Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-Strategy FlexTerm Contact Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-Strategy FlexTerm Contact Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . . . . Non-Isolated Analog Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Output FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Output FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . . . . Non-Isolated Analog Output FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Extender Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Unit (OBU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2 5-5-4 5-5-5 5-5-5 5-5-6 5-5-7 5-5-8 5-5-10 5-5-11 5-5-12 5-5-13 5-5-13 5-5-14 5-5-14 5-5-15 5-5-16 5-5-17 5-5-18 5-5-19 5-5-20 5-5-21 5-5-24 5-5-25 5-5-26 5-5-27 5-5-29 5-5-30 5-5-32 5-5-33 5-5-34 RS3: Service Manual Contents SV: xxi Chapter 6: Multipoint I/O Section 1: Multipoint I/O Installation and System Wiring . . . . . . . . . . . . . . . 6-1-1 Multipoint I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Address Jumpers . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Scanning Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O FIM Redundancy and Online Replacement . . . . . . . . . . . . . . . . . . . Multipoint I/O FIM Online Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O FIM Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel FIM Power Wiring . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Communication Wiring . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Communication Wiring: Online Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Communication Wiring: Redundancy . . 6-1-4 6-1-4 6-1-5 6-1-6 6-1-6 6-1-6 6-1-8 6-1-8 6-1-8 6-1-10 Communication Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1 Remote Communications Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel II . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel II Installation . . . . . . . . . . . . . Remote Communications Termination Panel II Wiring . . . . . . . . . . . . . . . . . Remote Communications Termination Panel II Jumpers . . . . . . . . . . . . . . . Remote Communications Termination Panel I . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel I Installation . . . . . . . . . . . . . Remote Communications Termination Panel I Wiring . . . . . . . . . . . . . . . . . Remote Communications Termination Panel I Jumpers . . . . . . . . . . . . . . . Fiber Optic I/O Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Communications Wiring . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Fiber Optic Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-2 6-2-4 6-2-6 6-2-6 6-2-8 6-2-9 6-2-9 6-2-9 6-2-10 6-2-11 6-2-14 6-2-15 6-2-15 6-2-16 Multipoint Discrete I/O (MDIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1 Direct Discrete Termination Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Installation . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Field Wiring . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Jumpers . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-FIM Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-3 6-3-4 6-3-8 6-3-9 6-3-10 6-3-13 6-3-14 6-3-16 6-3-16 6-3-21 6-3-22 6-3-23 Section 2: Section 3: RS3: Service Manual 6-1-10 6-1-11 Contents SV: xxii Section 4: Multi-FIM Discrete Termination Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-FIM Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Field Wiring Labels . . . . . . . . . . . . . . Isolated Discrete Termination Panel Field Wiring Output Points . . . . . . . . Isolated Discrete Termination Panel Field Wiring Input Points . . . . . . . . . . Isolated Discrete Termination Panel Solid State Relays . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Field Wiring . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Label . . . . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Solid State Relays . . . . . . Discrete Field Interface Module (FIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM Online Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM LED Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-25 6-3-26 6-3-28 6-3-31 6-3-33 6-3-36 6-3-37 6-3-38 6-3-39 6-3-40 6-3-41 6-3-43 6-3-43 6-3-44 6-3-45 6-3-46 6-3-48 6-3-48 6-3-49 6-3-50 6-3-51 Multipoint Analog I/O (MAIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1 Multipoint Analog I/O Termination Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist for CE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shield Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Point Type Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Powered Input Point with External Ground Reference . . . . . . . . . . . . Self-Powered Input Point with Ground Reference at Termination Panel . Marshaling Panel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring -- Output Points . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring -- Input Points . . . . . . . . . . . . . . . . . MAIO Termination Panel labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-2 6-4-4 6-4-7 6-4-7 6-4-7 6-4-9 6-4-9 6-4-10 6-4-10 6-4-11 6-4-12 6-4-13 6-4-14 6-4-15 6-4-15 6-4-16 6-4-16 6-4-17 6-4-19 6-4-19 6-4-20 6-4-21 6-4-22 6-4-25 RS3: Service Manual Contents SV: xxiii Section 5: Section 6: MAIO Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module (LPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIM Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-Point Input FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-Point Output FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-Point Input FIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIM LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIM LED Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single FIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant FIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failed FIM Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-27 6-4-28 6-4-29 6-4-32 6-4-32 6-4-33 6-4-33 6-4-35 6-4-38 6-4-39 6-4-41 6-4-41 6-4-42 6-4-43 6-4-44 6-4-46 6-4-48 6-4-49 6-4-50 6-4-50 6-4-50 6-4-51 Multipoint I/O Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1 Standard Remote Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-2 Intrinsic Safety (IS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1 Elcon Series 1000 IS Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel for Discrete Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Discrete Cross Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Discrete IS Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel for Analog Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Analog Cross Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Analog IS Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Common Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL IS Termination Panel for Discrete Applications . . . . . . . . . . . . . . . . . . . . . . . . Mapping I/O points to MTL Discrete Isolators . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-3 6-6-6 6-6-7 6-6-8 6-6-9 6-6-10 6-6-10 6-6-11 6-6-12 6-6-12 6-6-12 6-6-12 6-6-12 6-6-13 6-6-14 6-6-18 6-6-19 6-6-19 6-6-19 6-6-19 RS3: Service Manual Contents SV: xxiv Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Fault Detection (LFD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL Discrete Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel A Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel B Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL IS Termination Panel for Analog Applications . . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL Analog Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-19 6-6-20 6-6-20 6-6-21 6-6-23 6-6-24 6-6-25 6-6-28 6-6-28 6-6-28 6-6-28 6-6-28 6-6-28 6-6-29 6-6-29 Chapter 7: PeerWay Interface Devices Section 1: System Resource Unit (SRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1 Section 2: Supervisory Computer Interface (SCI) . . . . . . . . . . . . . . . . . . . . . . 7-2-1 RS-232C Asynchronous Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . RS-422 Asynchronous Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 Asynchronous Protocol Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist for CE Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Clocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIA Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-3 7-2-6 7-2-8 7-2-9 7-2-11 7-2-12 7-2-13 7-2-14 7-2-15 Highway Interface Adapter (HIA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-1 HIA Direct Connection of PeerWays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIA Connection of PeerWays Using Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for the HIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for HIA Direct Connection . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for HIA Connection Using Modems . . . . . . . . . . . . Checklist for CE Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure HIA Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIA Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-3 7-3-5 7-3-7 7-3-7 7-3-7 7-3-8 7-3-9 7-3-11 VAX/PeerWay Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-1 QBI Hardware Kit for the MicroVAX II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MicroVAX II -- PeerWay Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QBI Hardware Kit for the VAX 3xxx and VAX 4xxx . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-3 7-4-4 7-4-5 Section 3: Section 4: RS3: Service Manual Contents SV: xxv Section 5: Section 6: VAX 3xxx/VAX 4xxx -- PeerWay Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Marshaling Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Board 1 (CPU Card) Jumpers . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Board 2 (PeerWay Interface Card) Jumpers . . . . . . . . . VAX QBUS Interface Board 2 (PeerWay Interface Card) LEDs . . . . . . . . . . . 7-4-6 7-4-7 7-4-8 7-4-10 7-4-13 7-4-15 Diogenes Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-1 OI NV Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Interface Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Interface TI Communications Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Communication Convertor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-4 7-5-5 7-5-6 7-5-7 RS3 Network Interface (RNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-1 RNI PeerWay Node Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI System Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boot Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crash Dumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI LEDs and Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-3 7-6-4 7-6-6 7-6-6 7-6-6 7-6-7 7-6-8 7-6-9 7-6-10 Chapter 8: Calibration Section 1: Calibrating Serial I/O Field Interface Cards . . . . . . . . . . . . . . . . . 8-1-1 Serial I/O Analog Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Serial I/O Analog Output Points . . . . . . . . . . . . . . . . . Calibrating Serial I/O Analog Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . Calibrating Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-2 8-1-3 8-1-4 8-1-5 8-1-6 8-1-7 Calibrating Temperature Input FICs . . . . . . . . . . . . . . . . . . . . . . . . 8-2-1 Temperature Input FIC Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple Sensor Calibration Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple Sensor Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2-2 8-2-6 8-2-7 Calibrating Pulse Input FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3-1 Pulse Input FICs Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3-2 Calibrating MUX FEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-1 Entering Calibration Constants for Multiplexer FEMs . . . . . . . . . . . . . . . . . . . . . . . Calibrating Voltage Input and Thermocouple FEMs . . . . . . . . . . . . . . . . . . . . . . . . Checking and Calibrating Voltage Input and Thermocouple FEMs . . . . . . . . . 8-4-2 8-4-3 8-4-5 Section 2: Section 3: Section 4: RS3: Service Manual Contents SV: xxvi Section 5: Section 6: Calibrating 4--20 mA FEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Calibrating the 4--20 mA FEM . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of RTD FEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking RTD FEM Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-7 8-4-8 8-4-9 8-4-10 Calibrating Analog I/O Field Interface Cards . . . . . . . . . . . . . . . . 8-5-1 Analog I/O Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Analog I/O Output Points . . . . . . . . . . . . . . . . . . . . . . Calibrating Non-Isolated Analog I/O Output Points . . . . . . . . . . . . . . . . . . . . . . Calibrating Isolated Output FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Analog I/O Input Points Setup Using Current Input . . . . . . . . . Calibrating Analog I/O Input Points Setup Using Voltage Input . . . . . . . . . Calibrating Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-3 8-5-4 8-5-6 8-5-7 8-5-8 8-5-9 8-5-10 8-5-10 8-5-11 8-5-12 Calibrating Multipoint Analog I/O (MAIO) Output and Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6-1 Checking and Calibrating MAIO Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Calibrating MAIO Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6-1 8-6-4 Chapter 9: Maintenance Section 1: Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-1 Cleaning Tape Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Floppy Disk Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Trackball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Console Fan Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Command Console Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Cabinet Filters and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Door Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Fan Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Card Cage, HIA, SCI, and SRU Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Cabinet Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Active Hardware Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Glare Filter on a Command Console CRT . . . . . . . . . . . . . . . . . . . . . Degaussing a Command Console CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Diagnostic Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Off-Line Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-4 9-1-4 9-1-5 9-1-6 9-1-6 9-1-8 9-1-9 9-1-9 9-1-9 9-1-10 9-1-11 9-1-12 9-1-13 9-1-14 9-1-14 9-1-15 9-1-16 9-1-17 9-1-18 9-1-19 RS3: Service Manual Contents SV: xxvii Section 2: Section 3: ControlFile Power Regulator Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Power Regulator Card Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Interface (OI) Power Regulator Card . . . . . . . . . . . . . . . . . . . . . . . . . . System Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the AC/DC Power Supply Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the AC/DC Power Supply Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Backup Cards in Redundant Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Redundant Coordinator Processor Cards . . . . . . . . . . . . . . . . . . . . . Checking Redundant Controller Processor Cards . . . . . . . . . . . . . . . . . . . . . . . Removing and Installing Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan (System Power Supply Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-19 9-1-21 9-1-24 9-1-26 9-1-27 9-1-28 9-1-29 9-1-29 9-1-30 9-1-31 9-1-32 9-1-32 9-1-32 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-1 AC/DC Power Supply Battery and Charger Replacement . . . . . . . . . . . . . . . . . . . OI NV RAM Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Command and Basic Command Console Parts Replacement . . . . . . . . . . . . . . . Command Console Hard Disk Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Command Console Keyboard, Tape, or Floppy Disk Removal . . . . . . . . . . . . FlexTerm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MultiLoop and Single-Strategy FlexTerm Replacement . . . . . . . . . . . . . . . . . . Contact FlexTerm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-2 9-2-4 9-2-5 9-2-6 9-2-9 9-2-11 9-2-11 9-2-13 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3-1 Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3-1 9-3-2 9-3-2 9-3-3 9-3-3 Chapter 10: Troubleshooting Section 1: Troubleshooting the Power System . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 Section 2: Troubleshooting a PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1 PeerWay Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plant Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Performance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Overview Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen General Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Interval Controller (TIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIC Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1 10-2-2 10-2-3 10-2-9 10-2-12 10-2-13 10-2-13 10-2-13 10-2-14 RS3: Service Manual Contents SV: xxviii Section 3: Section 4: Section 5: Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Broadcast Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point-To-Point Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Field Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Columns 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Lower Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample PeerWay Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detecting a PeerWay Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the PeerWay Overview Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing a Console or SCI PeerWay Problem . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing a ControlFile PeerWay Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . With One ControlFile on the PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Multiple ControlFiles on the PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Cable Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Twinax PeerWay Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Fiber Optic PeerWay Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-14 10-2-14 10-2-14 10-2-14 10-2-15 10-2-15 10-2-15 10-2-19 10-2-21 10-2-23 10-2-25 10-2-29 10-2-30 10-2-31 10-2-33 10-2-35 10-2-36 10-2-37 10-2-37 10-2-39 10-2-40 10-2-41 10-2-42 Troubleshooting Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1 General Console Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Power-Up Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Off-Line Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Controller Memory Dump Capture . . . . . . . . . . . . . . . . . . . . . . . . . . Other Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Memory Dump Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Node Dump Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Confidence Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRT Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting OI Card Cage Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2 10-3-3 10-3-8 10-3-12 10-3-12 10-3-14 10-3-15 10-3-16 10-3-19 10-3-20 10-3-21 10-3-22 10-3-24 Troubleshooting ControlFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1 ControlFile Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wipe Bubble Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-7 10-4-9 Troubleshooting Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1 Restoring Redundant FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Serial Input/Output . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Analog Input/Output . . . . . . . . . . . . . . . . . . . . . . . 10-5-2 10-5-3 10-5-8 RS3: Service Manual Contents SV: xxix Field I/O Status Screen (FIC Status Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIC Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RBL Controller and Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13 10-5-18 10-5-21 Troubleshooting PeerWay Interface Devices . . . . . . . . . . . . . . . . 10-6-1 OI Bubble Memory Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1 Appendix A: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B: IEC and ISO Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C: Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Section 6: Appendixes RS3: Service Manual Contents SV: xxx RS3: Service Manual Contents 10P56988101 10P56988111 RS3t Service Manual Chapter 5: Serial and Analog I/O Section 1: Analog Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1 Analog Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Card Cage Address Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card III / IV / V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card III / IV / V Communication Wiring . . . . . . Communications Connect Card III / IV / V Jumpers . . . . . . . . . . . . . . . . . . Communications Connect Card II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications Connect Card II Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . Analog Transfer Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card (OBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Card Cage Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard . . . . . . . . . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard Jumpers . . . . . . . . . . . . Analog FIC W/Smart Transmitter Daughterboard Fuses . . . . . . . . . . . . . . Smart Transmitter Daughterboard Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter Daughterboard Installation . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse I/O FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2 5-1-3 5-1-4 5-1-6 5-1-7 5-1-8 5-1-10 5-1-10 5-1-13 5-1-16 5-1-17 5-1-18 5-1-21 5-1-21 5-1-22 5-1-23 5-1-24 5-1-28 5-1-30 5-1-31 5-1-34 5-1-35 5-1-36 5-1-37 5-1-37 5-1-37 5-1-38 5-1-40 5-1-41 5-1-43 5-1-44 5-1-45 5-1-46 5-1-51 5-1-52 RS3: Serial and Analog I/O Contents SV: ii Section 2: Section 3: Section 4: Temperature Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Extender Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Junction Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marshaling Panel Auxiliary Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-53 5-1-54 5-1-55 5-1-58 5-1-58 Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1 Contact Card Cage and Contact FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage FIC Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm FIC Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FlexTerm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Jumpers . . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Fuses . . . . . . . . . . . . . . . . . . . . Contact Termination Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Termination Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Termination Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Marshaling Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Isolator Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Card Cage and Contact FlexTerm Extender Card . . . . . . . . . . . . . . . . . . 5-2-2 5-2-4 5-2-5 5-2-6 5-2-7 5-2-8 5-2-8 5-2-10 5-2-12 5-2-13 5-2-14 5-2-15 5-2-16 5-2-17 5-2-19 5-2-20 5-2-22 5-2-23 5-2-25 5-2-26 5-2-27 5-2-28 Multiplexer FlexTerm Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-1 MUX FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Power Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Power Regulator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Communication Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Marshaling Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTD MUX Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUX Front End Modules (FEMs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple and Voltage FEM and Universal Voltage FEM . . . . . . . . . . . . . 5-3-2 5-3-4 5-3-5 5-3-5 5-3-7 5-3-7 5-3-9 5-3-10 5-3-14 5-3-16 PLC (Programmable Logic Controller) Hardware . . . . . . . . . . . . 5-4-1 PLC FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC FlexTerm Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLC Controller Processor Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-2 5-4-8 5-4-9 5-4-10 RS3: Serial and Analog I/O Contents SV: iii Section 5: PLC Port I/O Card Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS232 Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS232 Port I/O Card RS232 Pin Assignments . . . . . . . . . . . . . . . . RS422/RS232 Port I/O Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS232 Port I/O Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS232 Port I/O Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS422 Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS422 Port I/O Card RS422 Pin Assignments . . . . . . . . . . . . . . . . RS422/RS422 Port I/O Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS422 Port I/O Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS422/RS422 Port I/O Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-11 5-4-13 5-4-13 5-4-15 5-4-16 5-4-17 5-4-19 5-4-20 5-4-22 5-4-22 5-4-23 5-4-24 Multi-Loop and Single-Strategy FlexTerm Hardware . . . . . . . . . 5-5-1 Multi--Loop FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single--Strategy FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single--Strategy FlexTerm Analog Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single--Strategy FlexTerm Contact Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single--Strategy FlexTerm Contact Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . . . Non--Isolated Analog Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Transmitter FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Output FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Output FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . . . . Non--Isolated Analog Output FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . Non--Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIC Extender Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Bypass Unit (OBU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2 5-5-4 5-5-5 5-5-5 5-5-6 5-5-7 5-5-8 5-5-10 5-5-11 5-5-12 5-5-13 5-5-13 5-5-14 5-5-14 5-5-15 5-5-16 5-5-17 5-5-18 5-5-19 5-5-20 5-5-21 5-5-24 5-5-25 5-5-26 5-5-27 5-5-29 5-5-30 5-5-32 5-5-33 5-5-34 RS3: Serial and Analog I/O Contents SV: iv List of Figures Figure Page 5.1.1 Analog Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2 5.1.2 Analog Card Cage Address Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-3 5.1.3 Nonredundant Controller Processor Operation . . . . . . . . . . . . . . . . . . . . 5-1-5 5.1.4 Redundant Controller Processor Operation . . . . . . . . . . . . . . . . . . . . . . . 5-1-5 5.1.5 Communications Connect Card III, IV, or V Used With Multipoint I/O . 5-1-6 5.1.6 Communications Connect Card III / IV / V Block Diagram . . . . . . . . . . 5-1-7 5.1.7 Communications Connect Card III / IV / V . . . . . . . . . . . . . . . . . . . . . . . . 5-1-8 5.1.8 Comm Connect Card II Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . 5-1-10 5.1.9 Analog Transfer Card Redundancy Positions . . . . . . . . . . . . . . . . . . . . . 5-1-13 5.1.10 Analog Transfer Card Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . 5-1-14 5.1.11 Analog Transfer Card LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . . 5-1-16 5.1.12 Analog Transfer Card Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-17 5.1.13 Output Bypass Card Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-18 5.1.14 Output Bypass Card Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-20 5.1.15 Output Bypass Card Fuse and Jumper Locations . . . . . . . . . . . . . . . . . 5-1-22 5.1.16 Analog Field Interface Card Power Supply and Microprocessor . . . . . 5-1-25 5.1.17 Typical Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-26 5.1.18 Typical Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-27 5.1.19 Analog FIC Redundancy Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-28 5.1.20 Analog FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-30 5.1.21 Analog FIC Revision B or Later Jumper Locations . . . . . . . . . . . . . . . . . 5-1-32 5.1.22 Analog FIC (Earlier Version) Jumper Locations . . . . . . . . . . . . . . . . . . . 5-1-32 5.1.23 Analog FIC Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-34 5.1.24 Analog FIC W/Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . 5-1-36 5.1.25 Analog FIC Smart Transmitter Daughterboard LEDs . . . . . . . . . . . . . . . 5-1-40 5.1.26 Pulse I/O FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-43 5.1.27 Pulse I/O FIC Card Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . 5-1-44 5.1.28 Temperature Input FIC Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . 5-1-47 5.1.29 Field Wiring Terminations for a Temperature Input FIC Cond for a 3-wire RTD Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-49 5.1.30 Field Wiring Terminations for an RTD Application with External Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-49 5.1.31 Field Wiring Terminations for a Thermocouple and Cold Junction Compensator RTD Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-50 RS3: Serial and Analog I/O Contents SV: v 5.1.32 Temperature Input FIC LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-51 5.1.33 Temperature Input FIC Fuse and Jumper Positions . . . . . . . . . . . . . . . . 5-1-52 5.1.34 Analog Marshaling Panel 1984--2415--0001 . . . . . . . . . . . . . . . . . . . . . . 5-1-55 5.1.35 European Analog Marshaling Panel 10P54620001 . . . . . . . . . . . . . . . . 5-1-55 5.1.36 Analog Marshaling Panel 1984--2512--0001 . . . . . . . . . . . . . . . . . . . . . . 5-1-56 5.1.37 Marshaling Panel Auxiliary Terminal Block . . . . . . . . . . . . . . . . . . . . . . . 5-1-57 5.1.38 Auxiliary Terminal Block Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-58 5.1.39 4--20 mA Application -- Redundancy Loop Power Mismatch . . . . . . . . . 5-1-58 5.1.40 4--20 mA Input Application -- External Supply and Constant Loop Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-59 5.1.41 Pulse Application -- Simple DC Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-59 5.1.42 Pulse Application -- DC Block/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-60 5.1.43 Pulse Application -- Low Pass Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-60 5.2.1 Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-4 5.2.2 FIC Addressing in a Contact Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-5 5.2.3 Contact Card Cage Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-6 5.2.4 Contact FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-7 5.2.5 FIC Addressing in Contact FlexTerms . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-8 5.2.6 Contact FlexTerm Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-9 5.2.7 Contact Card Cage and Contact FlexTerm Jumper Locations . . . . . . . 5-2-10 5.2.8 Remote Marshalling Connectors Label . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-11 5.2.9 Contact Termination Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-13 5.2.10 Contact FlexTerm Field Wiring Using a Contact Termination Board . . 5-2-14 5.2.11 Contact FlexTerm System Power Wiring Using a Contact Termination Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-14 5.2.12 Contact Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-16 5.2.13 Contact Marshaling Panel Wiring Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-17 5.2.14 Contact Marshaling Panel Field Wiring: Example 1 . . . . . . . . . . . . . . . 5-2-18 5.2.15 Contact Marshaling Panel Field Wiring: Example 2 . . . . . . . . . . . . . . . 5-2-19 5.2.16 Discrete Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-22 5.2.17 Contact FIC Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-24 5.2.18 Contact Field Interface Card LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-25 5.2.19 Contact FIC 1984--1460--000x Fuse and Jumper Locations . . . . . . . . . 5-2-26 5.2.20 Contact FIC 1984--1304--000x Fuse and Jumper Location . . . . . . . . . . 5-2-26 5.3.1 Multiplexer FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-2 5.3.2 Two MUX FlexTerms Connected to a Controller Card . . . . . . . . . . . . . . 5-3-3 5.3.3 Multiplexer Power Regulator Functional Diagram . . . . . . . . . . . . . . . . . . 5-3-4 5.3.4 MUX Communication Card Functional Diagram . . . . . . . . . . . . . . . . . . . 5-3-5 RS3: Serial and Analog I/O Contents SV: vi 5.3.5 Connecting a Two-Wire RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-12 5.3.6 Connecting a Three-Wire RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-13 5.3.7 Connecting a Four-Wire RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-13 5.3.8 Securing a FEM in the MUX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-15 5.3.9 RTD Input FEM Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-16 5.3.10 Field Termination of Four-Wire and Three-Wire RTDs . . . . . . . . . . . . . . 5-3-17 5.3.11 Field Termination of a Two-Wire RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-18 5.4.1 PLC FlexTerm 10P5320000x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-3 5.4.2 PLC FlexTerm 1984--2409--000x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-4 5.4.3 PLC Flexterm Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-5 5.4.4 PLC Cabling for Four PLC Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-6 5.4.5 Allen-Bradley Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-7 5.4.6 PLC Controller Processor Redundancy Connections . . . . . . . . . . . . . . . 5-4-10 5.4.7 Port I/O Redundancy with Allen-Bradley PLC System . . . . . . . . . . . . . . 5-4-11 5.4.8 Port I/O Redundancy with Modicon PLC System . . . . . . . . . . . . . . . . . . 5-4-12 5.4.9 RS-422/RS-232 Port I/O Card Block Diagram . . . . . . . . . . . . . . . . . . . . 5-4-14 5.4.10 Port I/O Card RS-422/RS-232 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-16 5.4.11 RS-422/RS-232 Port I/O CARD Fuse and Jumpers . . . . . . . . . . . . . . . . 5-4-17 5.4.12 RS-422/RS-422 Port I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-21 5.4.13 Port I/O Card RS-422/RS-422 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-22 5.4.14 RS-422/RS-422 Port I/O Card Fuse and Jumpers . . . . . . . . . . . . . . . . . 5-4-23 5.5.1 MultiLoop and Single-Strategy FlexTerms . . . . . . . . . . . . . . . . . . . . . . . . 5-5-1 5.5.2 MultiLoop FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2 5.5.3 Typical MultiLoop FlexTerm Field Termination . . . . . . . . . . . . . . . . . . . . . 5-5-3 5.5.4 Single-Strategy FlexTerm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-4 5.5.5 Single-Strategy Contact I/O Wiring with Contact Termination Panel . . 5-5-5 5.5.6 Non-Isolated Analog Input Field Interface Card Block Diagram . . . . . . 5-5-8 .5.7 Non-Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . 5-5-10 5.5.8 Non-Isolated Analog Input FIC Fuse and Jumper Location . . . . . . . . . 5-5-11 5.5.9 Smart Transmitter FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . . . . 5-5-13 5.5.10 Smart Transmitter FIC Fuse and Jumper Locations . . . . . . . . . . . . . . . 5-5-14 5.5.11 Isolated Analog Input FIC Functional Diagram . . . . . . . . . . . . . . . . . . . . 5-5-15 5.5.12 Isolated Analog Input FIC LEDs and Test Points . . . . . . . . . . . . . . . . . . 5-5-16 5.5.13 Isolated Analog Input FIC Fuse and Jumper Location . . . . . . . . . . . . . . 5-5-17 5.5.14 Analog Input Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-19 5.5.15 Non-Isolated Analog Output FIC Functional Diagram . . . . . . . . . . . . . . 5-5-23 5.5.16 Non-Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . 5-5-24 RS3: Serial and Analog I/O Contents SV: vii 5.5.17 1985--1490--000x Non-Isolated Analog Output FIC Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-25 5.5.18 1984--1273--000x Non-Isolated Analog Output FIC Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-25 5.5.19 Isolated Analog Output FIC Functional Diagram . . . . . . . . . . . . . . . . . . 5-5-28 5.5.20 Isolated Analog Output FIC LEDs and Test Points . . . . . . . . . . . . . . . . . 5-5-29 5.5.21 1984--1334--000x Isolated Analog Output FIC Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-30 5.5.22 1984--1325--000x and --1469 Isolated Analog Input FIC Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-30 5.5.23 Output Bypass Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-34 5.5.24 Output Bypass Unit Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-36 5.5.25 Connecting the Output Bypass Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-38 RS3: Serial and Analog I/O Contents SV: viii List of Tables Table Page 5.1.1. Cage Address Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-9 5.1.2. Controller Redundancy Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . 5-1-9 5.1.3. Location Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-10 5.1.4. Cage Address Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-11 5.1.5. Comm Line Select Jumper Positions for Comm Connect II (1984--2491--000x) Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-11 5.1.6. Controller Redundancy Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . 5-1-11 5.1.7. Location Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-12 5.1.8. Analog Transfer Card Fuse Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-17 5.1.9. Output Bypass Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-22 5.1.10. Analog FIC Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-27 5.1.11. Analog FIC Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-33 5.1.12. Analog FIC Fuse Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-34 5.1.13. Pulse I/O FIC Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-41 5.1.14. Pulse I/O FIC Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-42 5.1.15. Pulse I/O FIC Card Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-44 5.1.16. Pulse I/O Field Interface Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-45 5.1.17. Temperature Input FIC Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-48 5.1.18. Temperature Input FIC Card Jumper Positions . . . . . . . . . . . . . . . . . . . . 5-1-52 5.1.19. Temperature Input Field Interface Card Fuses . . . . . . . . . . . . . . . . . . . . 5-1-53 5.1.20. European Analog Marshaling Panel 10P54620001 Fuses . . . . . . . . . . 5-1-55 5.2.1. Comparison of Contact Card Cage and Contact FlexTerm Assemblies 5-2-2 5.2.2. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-3 5.2.3. Contact Card Cage and Contact FlexTerm Jumper Positions . . . . . . . 5-2-10 5.2.4. Contact Card Cage and Contact FlexTerm Fuses . . . . . . . . . . . . . . . . . 5-2-12 5.2.5. Contact Termination Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-15 5.2.6. Contact Marshaling Panel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-17 5.2.7. Contact Marshalling Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-19 5.2.8. Optical Isolator Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-20 5.2.9. Maximum Current Ratings for Modules Mounted on Marshaling Panels 5-2-21 5.2.10. Contact FIC Specializations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-24 5.2.11. Contact Field Interface Card Jumper Positions . . . . . . . . . . . . . . . . . . . . 5-2-27 5.2.12. Contact Field Interface Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-27 RS3: Serial and Analog I/O Contents SV: ix 5.3.1. Voltage MUX Marshaling Panel Specifications . . . . . . . . . . . . . . . . . . . . 5-3-7 5.3.2. Wiring Voltage or Current MUX Marshaling Panel to FEM ......... 5-3-8 5.3.3. 4--20 mA MUX Marshaling Panel Specifications . . . . . . . . . . . . . . . . . . . 5-3-9 5.3.4. RTD MUX Marshaling Panel Specifications . . . . . . . . . . . . . . . . . . . . . . . 5-3-10 5.3.5. Wiring RTD MUX Marshaling Panel to FEM ..................... 5-3-11 5.4.1. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-2 5.4.2. PLC FlexTerm Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-8 5.4.3. Parts Replacement for the RS-422/RS-232 Port I/O Card ......... 5-4-13 5.4.4. RS-232C Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-15 5.4.5. RS-422/RS-232 Port I/O Card Jumper Positions . . . . . . . . . . . . . . . . . . 5-4-19 5.4.6. RS-422/RS-232 Port I/O Card Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-19 5.4.7. Parts Replacement for the RS-422/RS-232 Port I/O Card ......... 5-4-20 5.4.8. RS-422 Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-22 5.4.9. RS-422/RS-422 Port I/O Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-24 5.4.10. RS-422/RS-422 Port I/O Card Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-24 5.5.1. Contact Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-6 5.5.2. Non-Isolated Analog Input FIC Jumper Positions . . . . . . . . . . . . . . . . . . 5-5-11 5.5.3. Non-Isolated Analog Input FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-12 5.5.4. Smart Transmitter FIC Jumper Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-14 5.5.5. Smart Transmitter FIC Fuse Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-14 5.5.6. Isolated Analog Output FIC Jumper Positions . . . . . . . . . . . . . . . . . . . . 5-5-17 5.5.7. Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-18 5.5.8. Non-Isolated Analog Output FIC Jumper Positions . . . . . . . . . . . . . . . . 5-5-26 5.5.9. Non-Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-26 5.5.10. Isolated Analog Output FIC Jumper Positions . . . . . . . . . . . . . . . . . . . . 5-5-31 5.5.11. Isolated Analog Output FIC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-32 RS3: Serial and Analog I/O Contents SV: x RS3: Serial and Analog I/O Contents SV: 5-1-1 Section 1: Analog Card Cage This section covers the Analog Card Cage and the devices that go with it including: D Communications Connect card D Analog Transfer card D Output Bypass card D Analog Field Interface cards D Smart Transmitter Daughterboards D Pulse I/O Field Interface cards D Resistance Temperature Detector (RTD) Field Interface cards D Analog Extender card D Analog Marshaling Panels NOTE: The Analog Card Cage can be connected only to a Multipurpose Controller (MPC) Processor. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-2 Analog Card Cage The Analog Card Cage (1984--2526--0002) has slots for eight Field Interface cards (Analog 4--20 mA, Pulse, RTD/TC, Smart), two analog Transfer cards or Output Bypass cards, and one Comm Connect card. These cage slots are keyed. The card cage motherboard (1984--2597--000x or 1984--1497--000x) provides all interconnection among cage slots, power connectors, and marshaling panel connectors. The printed wiring assembly (PWA) is marked “ANALOG I/O CAGE MOTHERBOARD”. Figure 5.1.1 shows the location of cards in the Analog Card Cage. Field Interface Card Slots 1 through 8 Comm Connect Card Marshaling Panel Connector Ä Ä Ä Ä Analog Transfer Cards or Output Bypass Card Smart Daughterboard Power Connections Figure 5.1.1. Analog Card Cage The Card Cage has no field termination capability and must be used with an Analog Marshaling Panel or distributed I/O termination panel. The Comm Connect card provides connection from the Analog Card Cage to the ControlFile Controller Processor (or processors). An installation using redundant Controller Processors must have an additional cable and jumpers must be set on the Comm Connect card, Contact FlexTerms, and comm termination panels. The Comm Connect card has eight lines to connect distributed I/O termination panels or a distant Analog Cage. Space at the right of the Analog Card Cage provides a vertical wiring channel with anchors to attach plastic wraps. Cabling can be routed from side panels. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-3 Analog Card Cage Address Label A label on the front of the Analog Cage records the hardware address. Figure 5.1.2 shows the Analog Cage label. Write the hardware address in the blanks provided. The address includes the ControlFile Node (numeric), the Controller slot (A--H), and the FlexTerm or Card Cage (A--D). Use the box beside each point number to record a tag or label. Locations for Output Bypass or Transfer cards and the Comm Connect are shown on the label. CONTROL FILE NODE 101 102 103 SLOT 1 201 202 203 SLOT 2 301 302 303 SLOT 3 CONTROLLER SLOT 401 402 403 SLOT 4 Output bypass or transfer card slots 1-- 4 501 502 503 SLOT 5 601 602 603 SLOT 6 FLEXTERM 701 702 703 SLOT 7 801 802 803 SLOT 8 Ä Ä Ä Ä Output bypass or transfer card slots 5-- 8 Comm connect card Figure 5.1.2. Analog Card Cage Address Label RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-4 Communications Connect Card The Communications Connect card comes in four models: D D D D Communications Connect Card V (10P54560001), marked “COMMUNICATIONS CONNECT V” on the PWA. Communications Connect Card IV (10P54530001), marked “COMMUNICATIONS CONNECT IV” on the PWA. Communications Connect Card III (1984--2543--0002), marked “COMMUNICATIONS CONNECT III” on the PWA. Communications Connect Card II (1984--2491--0001), marked “EIGHT LINE COMM CONNECT” on the PWA. The card fits in the last slot (far right) of the Analog Card Cage. This card connects the Controller Processor card to the next Analog card cage. The Communications Connect card has transient voltage protection for eight communications lines from the Field Interface Cards (FICs) or Field Interface Modules (FIMs) to the Controller Processor card. Each communications line has a transient suppression diode between the signal lines and communications ground. Communications ground is referenced to system ground at the Controller Processor card but allowed to float at the Analog Card Cage. A transient suppression network ties communications ground to chassis ground. The Communications Connect card has jumpers for: D Card Cage Address D Comm line Select (1984--2491--0001 only) D Controller Redundancy D Local or Remote Card Cage Location Control Cable 1984--2783--9045 or shielded Control Communication Cable 10P5590xxxx connects the ControlFile and the Communications Connect card. Refer to the Site Preparation and Installation Manual (SP) for detailed cabling examples, including EMC compliance requirements. Two identical 40-pin cable connectors allow a daisy-chain connection of multiple card cages to one Controller Processor or to a redundant pair of Controller Processor cards. A jumper for each connector selects Controller Processor card redundancy, in addition to the cable connection. Figure 5.1.3 shows normal (nonredundant) operation of card cages and the ControlFile. Figure 5.1.3 shows redundant operation. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-5 Control Cable to Controller Processor Comm Connect Card Analog Card Cage Daisy chain cable Comm Connect Card ControlFile Card Cage Controller processor card Analog Card Cage Daisy chain cable Comm Connect Card Analog Card Cage Figure 5.1.3. Nonredundant Controller Processor Operation Primary Controller Processor Card Control Cable to Primary Controller Processor Comm Connect Card Analog card cage ControlFile Card Cage Optional Redundant Controller Processor Card Daisy Chain Cable Comm Connect Card Analog Card Cage Cable to Redundant Controller Processor Figure 5.1.4. Redundant Controller Processor Operation RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-6 Communications Connect Card III / IV / V Figure 5.1.5 shows Communications Connect Card III, IV, or V used to connect Multipoint I/O Termination Panels, usually Discrete I/O. PeerWay A B A B ControlFile Control Cable Communication Connect Card III / IV / V MPC Controller Analog Card Cage Communication Cables Multipoint I/O Termination Panels Figure 5.1.5. Communications Connect Card III, IV, or V Used With Multipoint I/O RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-7 Figure 5.1.6 is a block diagram of Communications Connect Card III / IV / V. Controller Comm Line (typical) to FIC in Card Cage To Comm Cable Current Limiting To Comm Cable Shield TRANSORBS Analog Card Cage Address 1 2 3 TO FICs in Card Cage 1 2 3 Card Cage Location 1 Remote 2 3 ControlFile Area Controller Processor Redundancy 1 2 3 1 Normal 2 3 Redundant To Controller To Cabinet Ground Figure 5.1.6. Communications Connect Card III / IV / V Block Diagram Communications Connect Card III / IV / V Communication Wiring Up to eight shielded, twisted pair communication lines may be connected to TB--1 through TB--8 as shown in Figure 5.1.7. Communications Connect Card III, IV, or V has required wiring termination and transient protection and does not need a Communication Termination Panel. The communication lines may run directly to a Multipoint I/O Termination panel, usually Discrete I/O, or to a remote Analog Card Cage. Communication lines to a remote Analog Card Cage terminate at TB1 through TB8 of the remote Analog Card Cage. Warning The transient suppression networks are sufficient for cables within a building. For runs between buildings, put lightning arrestors where the cable enters the building. FRSI recommends metal conduit or a copper ground wire. (Or use a Fiber Optic I/O Converter.) RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-8 Communications Connect Card III / IV / V Jumpers Communications Connect Card III, IV, or V has three sets of jumpers. Figure 5.1.7 shows the jumper locations for these Communications Connect Cards (III: 1984--2543--000x, IV: 10P54530001, and V: 10P54560001). TB 1 Terminals for Communication Lines 1--8 (Each of these connections has +, -- ,shield) TB 2 TB 3 Connector for Controller 1 TB 4 Connector for Controller 2 TB 5 HD1, HD2 Card Cage Address TB 6 HD5 Card Cage Location HD4 A & B Controller Processor Redundancy TB 7 TB 8 Figure 5.1.7. Communications Connect Card III / IV / V Cage Address Jumpers: Jumpers (HD1, HD2) indicate the Card Cage address where the Communications Connect Card is installed. The address may be A, B, C, or D. The jumper positions are designated “1”, “2”, and “3” on one side and “ZERO” and “ONE” on the other side. Table 5.1.1 gives jumper values for the Cage Address jumpers (HD1, HD2). RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-9 Table 5.1.1. Cage Address Jumper Positions Card Cage Address Jumper HD1 Jumper HD2 A 1--2 ZERO 1--2 ZERO B 2--3 ONE 1--2 ZERO C 1--2 ZERO 2--3 ONE D 2--3 ONE 2--3 ONE Controller Redundancy Jumper: (HD4) indicates if the Controller Processor is configured as NORMAL (not redundant) or REDUNDANT. If the Controller Processor is redundant, you must set all associated jumpers indicating redundancy. Redundancy jumpers are on the Comm Connect card, the communication termination panels, and Contact Flexterm. Table 5.1.2 gives the Controller Redundancy jumper values. Table 5.1.2. Controller Redundancy Jumper Positions Jumper Controller Not Redundant Controller Redundant HD4 A 1--2 NORMAL 2--3 REDUNDANT HD4 B 1--2 NORMAL 2--3 REDUNDANT Location Jumper: (HD5) indicates whether the card cage is located at a remote I/O location or near the ControlFile. A card cage is in the ControlFile area if it is connected directly to the ControlFile with one or more Controller Cable(s) 10P5590xxxx or 1984--2783--xxxx or 1984--1259--xxxx or 1984--0083--xxxx (maximum length 200 feet). A card cage is at a remote I/O location if it is connected to the ControlFile via two comm termination panels. The Location jumper modifies transient protection, depending on the location of the card cage. Table 5.1.3 gives jumper values for the Location Jumper. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-10 Table 5.1.3. Location Jumper Positions Jumper Card Cage in ControlFile Area Card Cage in Remote Location HD5 2--3 CONTROL FILE AREA 1--2 REMOTE I/O Communications Connect Card II The Communications Connect Card II provides for up to eight communications lines that are gathered and connected to either J459 or J460. Communications Connect Card II Jumpers The Communications Connect Card II has four sets of jumpers. Figure 5.1.8 shows the jumper locations for the Communications Connect Card II (1984--2491--0001). HD5 Card Cage Location Connector for Controller 1 or Communication Cable J459 Connector for Controller 2 or Communication Cable HD4 A & B Controller Processor Redundancy J460 HD1, HD2 Card Cage Address HD3 A--J Comm Line Select Figure 5.1.8. Comm Connect Card II Jumper Locations Cage Address Jumpers: Jumpers (HD1, HD2) indicate whether the card cage is cage A, B, C, or D. The jumper positions are designated “1”, “2”, and “3” on one side and “ZERO” and “ONE” on the other side. A Controller Processor can be configured to control up to four Analog Card Cages (designated as A, B, C, or D). Configuration limitations normally restrict the connections to three Analog Card Cages. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-11 Table 5.1.4 gives jumper values for the Cage Address jumpers (HD1, HD2). Table 5.1.4. Cage Address Jumper Positions Card Cage Address Jumper HD1 Jumper HD2 Applies to: A 1--2 ZERO 1--2 ZERO Analog Card Cages B 2--3 ONE 1--2 ZERO Analog Card Cages C 1--2 ZERO 2--3 ONE Analog Card Cages D 2--3 ONE 2--3 ONE Analog Card Cages Comm Line Select Jumpers: (HD3 A--J) must be in the 2--3 position, to indicate 1--8 comm lines. Table 5.1.5 gives Comm Line Select jumper values for Comm Connect II. Table 5.1.5. Comm Line Select Jumper Positions for Comm Connect II (1984--2491--000x) Only Jumpers A--J Number of Comm Lines Connected 2--3 1--8 Controller Redundancy Jumper: (HD4) selects the Controller Processor’s NORMAL (not redundant) or REDUNDANT configuration. If redundant Controller Processors are used, all associated jumpers indicating redundancy must be in the redundant position. Redundancy jumpers are on the Comm Connect card, the Contact Flexterm, and the Communications Termination panels. Table 5.1.6 gives the Controller Redundancy jumper values. Table 5.1.6. Controller Redundancy Jumper Positions RS3: Serial and Analog I/O Jumper Controller Not Redundant Controller Redundant HD4 A 1--2 NORMAL 2--3 REDUNDANT HD4 B 1--2 NORMAL 2--3 REDUNDANT Analog Card Cage SV: 5-1-12 Location Jumper: (HD5) indicates if the card cage is at a remote I/O location or in the ControlFile area. A card cage is in the ControlFile area if it is connected directly to the ControlFile with one or more Controller Cables (maximum length 200 feet). A card cage is at a remote I/O location if it is connected to the ControlFile via two comm termination panels. The Location jumper selects transient protection appropriate to the location. Table 5.1.7 gives jumper values for the Location Jumper. Table 5.1.7. Location Jumper Positions RS3: Serial and Analog I/O Jumper Card Cage in ControlFile Area Card Cage in Remote Location HD5 2--3 CONTROL FILE AREA 1--2 REMOTE I/O Analog Card Cage SV: 5-1-13 Analog Transfer Card The Analog Transfer card (1984--2494--0001) is marked “ANALOG TRANSFER” on the PWA. In the Transfer card slot of the Analog Cage, it switches field signals from the primary Field Interface Card to the backup FIC for 1--3 or 1--7 redundancy. The card also collects status data from primary FICs and sends it to the backup FIC. Figure 5.1.9 shows card positions for 1--3 and 1--7 redundancy. The Transfer card is not used for 1--1 redundancy. With 1--3 redundancy, one Analog Transfer Card transfers control for FICs in slots 1 through 3 with the backup FIC in slot 4. With 1--3 redundancy, one Analog Transfer card transfers control for FICs in slots 5 through 7 with the backup FIC in slot 8 Ä Ä Ä Ä With 1--7 redundancy, two Analog Transfer cards are required for slots 1 through 7. Both cards are controlled by the backup FIC (in slot 8) with signals RSEL0, RSEL1, and RGRANT going from one Transfer card to the other. Figure 5.1.9. Analog Transfer Card Redundancy Positions Figure 5.1.10 is an Analog Transfer card function diagram of a backup FIC configured through an Redundant Input/Output Block (RIOB). Three lines from the backup FIC are a slot “address”: RSEL D 0,1, and 2 (redundancy select). The backup Field Interface Card (FIC) controls the Analog Transfer card with this set of address lines and a redundancy activation signal, RGRANTD (redundancy grant D). If I/O redundancy is not active, the backup FIC uses the address lines and short pulses on the RGRANTD line to send the state of the HELP line of each primary FIC to the RREQD line of the backup FIC. Between RGRANTD pulses, the Analog Transfer Card status is applied to Redundancy Request (RREQ), giving the backup FIC access to the status of cards it controls. The backup FIC indexes through addresses, scans slots and monitors the RREQ line. The Controller Processor determines if FICs are switched through the RREQ line. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-14 * Active Only On A Backup FIC Slot 8 Or Slot 4 (Backup) RSEL D 0,1,2* **Active Only On A Primary FIC D RREQ D* Field Signal Relay Drive RGRANT D* FIELD SIGNALS RELAY D HELP** TO RELAYS C B A E DISCONNECT** Slot 7 Or Slot 3 FIELD SIGNALS Address Control RELAY C HELP Disconnect Selector Logic DISCONNECT Slot 6 Or Slot 2 FIELD SIGNALS RELAY B HELP DISCONNECT Address Control RELAY A Slot 5 Or Slot 2 FIELD SIGNALS Status MultiPlexer HELP DISCONNECT 30V A 30V B STATUS Power Supply +15V + 5V RELAY E RGRANT Bidirectional Drive Circuitry RSEL RREQ To Other Analog Transfer Card Figure 5.1.10. Analog Transfer Card Functional Diagram RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-15 If the Controller orders a backup card to take over from a primary card, the RSEL0--RSEL2 lines continuously select the primary slot and the RGRANT line goes active and is held. Two A through E relays are energized to connect field signal lines from the primary FIC to the backup FIC. The disconnect signal for the primary FIC goes active, to open relays on the primary FIC and effectively disconnect it from the field signals. In a power failure, these FIC relays de-energize and disconnect the field device. Field signals are connected between Transfer cards through relay E on each card. The Analog Transfer Card status indication is “Good” if the card is present and the 5V and 15V power supplies are good. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-16 Analog Transfer Card LEDs and Test Points Two LEDs on the Analog Transfer card indicate a blown fuse and whether the power supply is operating. LEDs on the Field Interface card indicate if the Transfer card is active. Figure 5.1.11 shows the Analog Transfer card LEDs and test points. NOTE: The test points on some cards are blue-violet-grey; on others they are all violet. - To measure the loop current without disconnecting the loop: 1. Insert the negative lead of the milliameter into TPB (front row). 2. Insert the positive lead of the milliameter into TPS (back row). CAUTION Do not connect the milliameter leads to test points for two different points. Both loops could be disrupted, which could result in incorrect signals or damage to the FIC in one or both loops. TPB TPS Slot 1 or 5 Point 1 Slot 1 or 5 Point 2 Slot 1 or 5 Point 3 Slot 2 or 6 Point 1 Slot 2 or 6 Point 2 Slot 2 or 6 Point 3 Slot 3 or 7 Point 1 Slot 3 or 7 Point 2 Slot 3 or 7 Point 3 Slot 4 or 8 Point 1 Slot 4 or 8 Point 2 Slot 4 or 8 Point 3 R G 30 V Fuse Blown (DS2) LEDs The 30 VDC power fuse is blown. +5 V Status (DS1) Power is present on the card and the regulator is operational. Figure 5.1.11. Analog Transfer Card LEDs and Test Points RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-17 Analog Transfer Card Fuse Figure 5.1.12 shows the location of the Analog Transfer card fuse. Table 5.1.8 gives fuse data. F1 Figure 5.1.12. Analog Transfer Card Fuse Location Table 5.1.8. Analog Transfer Card Fuse Data Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G50382--0014 273.500 MSF 034.4216 1/2 A 125 V Plug-In RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-18 Output Bypass Card (OBC) The Output Bypass Card (1984--2551--0001) is plugged into one of two Output Bypass slots of the Analog Card Cage. It bypasses any selected Analog (4--20) FIC in the adjacent left four cage slots. The OBC supplies uninterrupted current to the field in place of an output FIC while the FIC is being replaced. It provides bumpless transfer into and out of bypass mode and allows local adjustment of the signal level. The OBC displays the value of the output current on a digital display on the card faceplate. The OBC has a “SLOT” pushbutton used to select the FIC to bypass. Figure 5.1.13 shows the OBC faceplate. FIELD · (mA) S L O T 1 2 3 4 5 6 7 8 BYPASS BALANCED MODE SLOT Figure 5.1.13. Output Bypass Card Faceplate Figure 5.1.14 is the OBC functional diagram. The OBC uses a onetime programmable MC68701 microprocessor with 4Kb of Erasable Programmable Read-Only Memory (EPROM). A watchdog circuit assures microprocessor startup when the OBC is powered on. The OBC has three operating modes: Diagnostics, Balance, and Bypass. Diagnostics mode is entered on power-up. The card runs self test diagnostics in this mode. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-19 Pressing the SLOT button exits Diagnostics mode and enters Balance mode for the first (leftmost) FIC. Pressing SLOT steps through the slots and back to Diagnostics mode. In Balance mode, the output current of the selected FIC is routed through the OBC. The OBC does not source current in the Balance mode. The FIC’s current value is in the “Field” area. If the measured current is in the normal range (3--21 mA), the green Balance LED lights on the faceplate of the OBC. If measured current is outside the normal range, the OBC displays the nearest in-range value. Pressing MODE exits Balance and enters Bypass mode. The transfer is bumpless for all in-range values. In Bypass mode, the OBC becomes the current source to the field device. The OBC puts out the current value displayed while in Balance mode. The Analog Output Block (AOB) will go into OVERRIDE mode. You can manually slew the output value with the raise [up arrow] and lower [down arrow] buttons. In Bypass mode, the OBC monitors the selected FIC output but does not send this output to the field. When the FIC output matches the current being sent by the OBC, the green Balance LED lights. If the FIC output does not match the OBC output, the OBC instructs the FIC to raise or lower its value. This lets a good FIC track the setting of the OBC and prepares for a bumpless transfer to control by the FIC. NOTE: The OBC does not measure actual current going to the field. It measures and displays the desired current value. If the output loop is open or shorted, the actual output current sent to the field will not match the desired value. Normal operation of the FIC is restored when the green Balance LED is lighted and the MODE button is pressed. The OBC returns control to the FIC and reenters Balance mode. The transfer is bumpless. NOTE: The AOB is left in MANUAL when control is returned to the FIC. Use of AUTOLOCK in the AOB will cause the AOB to return to AUTO. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-20 +30 VI2 +15 VI2 Power Regulator +30V A +8 VI1 --5 VI1 +5 V +30V B Return +5 V --5 VI1 +5 V N.C. POSITION MODE OPTO Isolator SLOT Analog To Digital Circuit + -- OBC Microprocessor UP +5 V Regulator IGND 1 Digital Display DOWN +8 VI1 To FIC Microprocessor /OBU /RAISE +5 V /LOWER + Watchdog Circuit IGND 2 OPTO Isolator Current Flow Sense Resistor 30 VI2 15 VI2 +15 V IGND 2 -Digital To Analog Circuit +5 V Regulator From FIC Output Circuit IGND 2 N.C. N.C. IGND 2 Field Load IGND 2 Figure 5.1.14. Output Bypass Card Functional Diagram RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-21 Output Bypass Card Operating Instructions NOTE: The FIC I/O Block faceplate shows OVERRIDE mode if the FIC is bypassed. The FIC I/O Block faceplate goes to MANUAL if the FIC is taken out of bypass (If Auto Lock field is “Yes,” it goes to AUTO mode). - To bypass an output FIC: 1. Plug the OBC in the “Output Bypass” slot next to the adjacent slots 1 through 4 or slots 5 through 8 of the Analog Card Cage. 2. If the OBC is properly connected, a lamp test begins and the numbers “8888” appear in the “Field” digital display. A slot or mode cannot be selected while the lamp test is in progress. 3. The OBC begins the 4--20 mA ramping self-diagnostic test. While the ramping test runs, a FIC is selected by pressing the SLOT pushbutton on the OBC faceplate. One of four FICs in adjacent slots to the left of the OBC can be selected. 4. The green Balance LED on the OBC lights automatically when the selected FIC current balances with the range in the OBC. The FIC current is displayed in the “Field” area of the OBC faceplate. 5. To bypass FIC operation to the OBC, press the MODE button on the OBC faceplate. When MODE is pressed, the red Bypass LED lights on the OBC, the green LED on the bypassed FIC flashes, and an alarm condition is annunciated at the console. The OBC is now the current source and the current is displayed in the “Field” area of the faceplate. 6. In BYPASS mode, the OBC current can be raised and lowered by pushing the “UP’ and “DOWN” pushbuttons on the faceplate. 7. To replace a FIC card, bypass it as in steps 1--5 above. An alarm is generated when removing the bypassed FIC from the card cage. Insert the replacement FIC into the card cage. The new FIC attempts to balance with the OBC current. Wait for the green Balance LED on the OBC to light. 8. Press the MODE button on the Output Bypass card to return control to the new FIC and to turn off the red Bypass LED. 9. Put the AOB into AUTO. It defaults to MANUAL after the override. Output Bypass Card LEDs Figure 5.1.13 shows the LEDs on the Output Bypass card faceplate. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-22 Output Bypass Card Fuses Figure 5.1.15 shows the locations of fuses on the Output Bypass card. Table 5.1.9 gives fuse data. LEDs F2 F1 Switches Figure 5.1.15. Output Bypass Card Fuse and Jumper Locations Table 5.1.9. Output Bypass Card Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G09140--0030 AGC 2 312002 -- -- 2 A 250 V Quick Acting F2 G50382--0009 -- -- 273.125 MSF 034.4210 1/8 A 125 V Plug-In RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-23 Analog Card Cage Field Interface Cards The Field Interface Cards (FIC) that can be used with the Analog Card Cage are: D Analog FIC (4--20 mA) D Analog FIC with Smart Transmitter Daughterboard D Smart Transmitter Daughterboard D Pulse I/O FIC D RTD/TC FIC The Analog Extender card can be used to move FICs outside of the Analog Card Cage for service access. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-24 Analog FIC The 10P54440002 and 1984--2518--000x Analog Field Interface cards (FICs), used with the MPC Analog Card Cage, provide an interface to analog inputs and outputs. The 10P54440002 and 1984--2518--0002 cards are functionally identical. The 10P54440002 card is EMC compliant. They are marked “FIC 4--20 MA” on the PWA. The analog FIC accepts a 4--20 mA input signal and provides a 4--20 mA field output signal. Each card can accommodate three points, with up to two input points and one output point, or three input points. The 4--20 mA Analog FIC converts up to three 4--20 mA input signals to digital input values and transmits them to the Controller Processor. The analog FIC can also receive a digital output from the Controller Processor card and convert it into a 4--20 mA analog output signal to provide analog inputs and outputs for the system. The card can be jumpered for various redundancy schemes -- normal or reverse action of the output signal (for the output to either hold or go to zero on a loss of communications with the Controller Processor); and for self powered or system powered field devices. The 10P54440002 and 1984--2518--0002 cards can support a Smart Transmitter through the installation of a Smart Transmitter Daughterboard. Figure 5.1.16 shows a functional diagram of the power supply and microprocessor portion of the card. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-25 Processor System Redundancy Circuitry I/O Card to Transfer Card or OBC Relay Drive Battery Backed RAM 8K Bytes 68701 Micro 2K EPROM RS-422 comm lines Serial Data to D/A 128 Byte RAM WD & Power Up/Down Reset Timer 5 Volt And 30 Volt Isolated Regulator 30 Volt ISO To Loop Power Supply 30 Volt Bus A 30 Volt Bus B SEL 1 SEL 2 SEL 3 DS4 Dual Pulse Input 1 NORM 2 3 REV Output Action Jumper Figure 5.1.16. Analog Field Interface Card Power Supply and Microprocessor Power is usually supplied to the card by a 30 volt DC bus but power can also be supplied by an external 24 to 32 volt DC power source for remote installations. The power regulator provides: D D D Non-isolated +5 volts to the microprocessor, memory, and associated circuits Isolated +5 volts for communications Three independent 30 volt sources, each source for one I/O point. Redundant power buses may be provided. Diodes provide isolation between buses. Each I/O point on the Field Interface card connects to the field wiring through marshaling panels. Each field signal line is individually fused. A transient suppression circuit protects the FIC against fault conditions by conducting fault currents at voltages above 47 volts between the field terminals and conducting to ground at a common mode voltage of 200 volts. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-26 Figure 5.1.17 shows a typical output circuit. The FIC input circuitry includes a 24 volt nominal loop power supply. A 4--20 mA signal is converted to 0.8 to 4.0 volts, filtered, and then turned into a series of timing pulses by a dual pulse converter. Pulses are optically isolated and go directly to the microprocessor timer subsystem. The MC68701 microprocessor has 128 bytes of scratchpad RAM and a 2K EPROM with diagnostics and a startup routine. The microprocessor system contains 8K bytes of “battery-backed” RAM memory that is not affected by power outages. Battery-backed RAM gives nonvolatile storage of the main operating code and calibration constants. The microprocessor looks at the pulses, extracts the timing data, and converts it to digital values. The digital values contain errors related to components in the input sections. Error correction is done locally on the FIC through calibration constants in the 8K RAM. Corrected values are digitally filtered, packed into a message, and sent to the Controller Processor cards. Serial Data To D/A Opt Isol Status Hold 1 2 Zero 3 From Microprocessor Dual Pulse Input 5V Ref Digital To Analog Converter Channel 3 Controlled Current Sink SEL 3 N.C. A To Marshaling Panel Terminals B Relay N.O. 1 System 2 3 Self Loop Power Jumper (HD31) S INPUT 3 Signal Condition 30 V ISO 3 Analog To Dual Pulse Converter 5V Ref 24 V Loop Power Figure 5.1.17. Typical Output Circuit Figure 5.1.18 shows a typical input circuit. For output, the Controller Processor card sends a digital value to the Field Interface card. The FIC then sends this digital value, adjusted by calibration constants, to the digital to analog converter circuitry through an optical isolator. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-27 Dual Pulse Input Channel 2 N.O. INPUT 2 Relay A To Marshalling Panel Terminals B To Optional Test Point Loop Power Jumper (HD21) S Analog To Dual Pulse Converter Signal Condition 1 System 2 3 Self SEL 2 30V ISO 2 5V Ref 24 Volt Loop Power = Cabinet Metal -- Transient Suppression Only Input 1 Circuit Similar To Input 2 Figure 5.1.18. Typical Input Circuit Table 5.1.10 lists the specifications of the analog FIC. Table 5.1.10. Analog FIC Specifications Specification Item Temperature 0--50° C Humidity 10--90% Power Supply voltage Nominal Minimum Maximum Minimum Battery Backup Current (typical) At 30 VDC At 24 VDC At 18 VDC Accuracy .1% of span Resolution over 4--20 mA span Drift/Temperature RS3: Serial and Analog I/O 24 VDC to 30 VDC 22 VDC 34 VDC 18 VDC 214 mA 260 mA 347 mA Input (A/D) 13 bits (0.012%) Output (D/A)12.4 bits (0.019%) .1% of span from 25° C to any temperature in 0--50° range Analog Card Cage SV: 5-1-28 Analog FIC Redundancy The 4--20 mA Isolated Analog FIC can be used in arrangements of 1--7, 1--3, and 1--1 redundancy. The Controller Processor card initiates the command to switch control from a suspect FIC to the backup FIC. Under normal operation, the three FIC relays that connect the card to the marshaling panel terminals are energized and closed. On a backup FIC the relays are de-energized and normally open. If the primary FIC fails, the Controller Processor card sends a signal to the backup FIC to de-energize, or open the relays on the failed FIC, thus removing it from the system. Figure 5.1.19 shows the redundancy positions. With 1--3 redundancy, the FIC in slot 4 backs up FICs in slots 1 through 3, and the FIC in slot 8 backs up FICs in slots 5 through 7. One Analog Transfer card is needed to reroute the field connections for each backup FIC. Ä Ä Ä Ä Analog Card Cage With 1--1 redundancy, the FIC in the right slot backs up the FIC to the left of it. No Analog Transfer card is needed. With 1--7 redundancy, the FIC in slot 8 backs up FICs in slots 1 through 7. Two Analog Transfer cards are needed to reroute field connections. Figure 5.1.19. Analog FIC Redundancy Positions NOTE: The revision level of the boot software in the redundant FIC must be equal (or higher) to any FIC that is backed up. 1--1 redundancy is not available with the MPCAS, MPCAP, and MPCAT Images. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-29 When a primary FIC with redundancy fails, the redundant FIC takes over. The failed FIC lights its red LED or flashes its green LED. Replace the failed FIC and determine that the new FIC has its green LED on and that the FIC Status screen shows no error for the FIC. The “Health” field of the primary FIC will still show “Bad”. Restore the original configuration to have redundancy effective again. CAUTION Do not pull the redundant FIC to force a switch back to the primary FIC. This introduces a “double hardware failure” and may result in unexpected operation. - To restore FIC redundancy: 1. Call up the Redundant Input/Output Block (RIOB) screen. 2. Put the RIOB in MANUAL. 3. Highlight the line: Reset Backup (Press enter) and press [ENTER]. This restores the primary FIC and resets the backup FIC for backup action. The Health field of the primary FIC will now show “Good”. 4. Put the RIOB in AUTO. Normal redundancy operation is restored. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-30 Analog FIC LEDs Figure 5.1.20 shows the Analog Field Interface Card LEDs. LEDs G R Y R CARD GOOD (DS1) No card faults are detected and the controller processor card is controlling the output current. Blinking LED indicates the FIC is not connected to the field (I/O redundancy) or the output is being controlled by the Output Bypass card. CARD FAULT (DS2) A card fault is detected or communications with the Controller Processor card have ceased. Indicates communications activity. The signal that enables the TX ENABLE transmit signal from the Field Interface card to the Controller (DS3) Processor card is active. 30 V FUSE BLOWN (DS4) Power fuse F1 has blown. This LED does not indicate the status of the fuses in the I/O loops. All fuses are installed in sockets and are removable without soldering. Figure 5.1.20. Analog FIC LEDs RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-31 Analog FIC Jumpers Four sets of jumpers can be set for the Analog FIC: D FAIL -- to control action of the card on communications failure. D OUT -- to control normal or reverse action of the output signal. D REDUNDANCY -- to control FIC redundancy. D PWR -- to select field or system power for field devices. The FAIL (HD1) jumper can be set either to HOLD or ZERO output on a communications failure. The OUT (HD2) jumper is set for either NORM or REVERSE action of the output. This jumper is no longer used by the software. The AOB block associated with the address should be set to control the output action. The jumper should be in the NORM position. The REDUNDANCY (HD4) jumpers set pins 1--2 for all redundancy schemes except 1--1. The jumpers are set to 1--2 for nonredundant applications. The revision A card uses jumper HD5 to set redundancy. The proper hardware and software must be present to have FIC redundancy. There are three sets of PWR jumpers (HD11, HD21, and HD31), one for each of the three I/O circuits. The PWR jumpers can be set to SYS (for powering the loop from the system), or to SELF (for powering the loop external to the system). HD11 corresponds to point xxxx01, HD21 to point xxxx02, and HD31 to xxxx03. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-32 There are two versions of the card, which differ in the location of the jumpers. The earlier version card uses an additional jumper (HD5) for redundancy. Figure 5.1.21 shows jumper locations on all but the earlier version card. PWR SYS 1 2 SELF 3 OUT ACT NORM HD2 REV FAIL HOLD 1 2 HD4 ZERO 3 1 1--7 HD1 2 3 1--1 REDUNDANCY HD11 PWR SYS 1 2 SELF 3 PWR SYS 1 2 SELF 3 HD21 HD31 Figure 5.1.21. Analog FIC Revision B or Later Jumper Locations Figure 5.1.22 shows the locations for the earlier version card. HD11 HD21 HD31 HD3 HD5 HD2 HD4 HD1 Figure 5.1.22. Analog FIC (Earlier Version) Jumper Locations RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-33 Table 5.1.11 gives jumper values for the Analog Field Interface card. Table 5.1.11. Analog FIC Jumper Positions Jumper Value Action FAIL HD1 HOLD 1--2 Hold output on failure. ZERO 2--3 Zero output on failure NORM 1--2 Normal output action (Jumper not used by software. Leave in the 1--2 position.) REV 2--3 Reversed output action (Jumper not used by software.) 1--2 1--7 redundancy or no redundancy 2--3 1--1 redundancy SYS 1--2 System power for external devices SELF 2--3 External devices are self powered OUT HD2 REDUNDANCY HD4 HD5 (Early version only) PWR HD11 HD21 HD31 RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-34 Analog FIC Fuses Figure 5.1.23 shows the locations of the fuses on the Analog FIC. Table 5.1.12 gives fuse data. F11 F12 F21 F22 F31 F32 F1 Figure 5.1.23. Analog FIC Fuse Locations Table 5.1.12. Analog FIC Fuse Data Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 C50382--0021 273002 MSF 034.4224 2 A 125 V Plug-In F11 F12 F21 F22 F31 F32 C50382--0011 273.250 MSF 034.4213 1/4 A 125 V Plug-In RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-35 Analog FIC W/Smart Transmitter Daughterboard Analog FIC with Smart Transmitter Daughterboard (1984--2519--000x) is a Analog FIC (1984--2518--0002) with a factory-installed Smart Transmitter Daughterboard Kit (1984--2483--000x). An EMC-compliant Analog FIC with Smart Transmitter Daughterboard (10P57240002) is a EMC-compliant Analog FIC (10P54440002) equipped with a factory-installed EMC-compliant Smart Transmitter Daughterboard (10P54500005). Aside from EMC compliance, the two card combinations are functionally identical. The Analog FIC with Smart Transmitter Daughterboard supports communications between a Smart transmitter and a MultiPurpose Controller Processor. The Smart Daughterboard lets the system communicate to a Smart device by sending digital information on top of the 4--20 mA signal. Smart Transmitter digital communication requires I/O block reconfiguration. Refer to the I/O Block Configuration Manual for information. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-36 Analog FIC W/Smart Transmitter Daughterboard LEDs The Analog FIC and the Smart Transmitter Daughterboard have LEDs. Figure 5.1.24 shows the combination. No card faults detected, the Controller Processor card is controlling the CARD GOOD output current. Blinking (Green) LED mean the FIC is not (DS11) connected to the field (I/O redundancy) or the output is being controlled by the Output Bypass card. CARD FAULT (Yellow) (DS2) A card fault is detected or communications with the controller processor card have ceased. TX ENABLE (Yellow) (DS3) Communications are active. The signal that enables the transmit signal from the FIC to the Controller Processor card is active. 30 V FUSE BLOWN (Red) (DS4) Power fuse F1 has blown. This LED does not show the status of fuses in the I/O loops. All fuses are installed in sockets and are removable without soldering. G Y Y Y Y Y R Y Y RTS REQUEST TO SEND (Yellow) (DS1) The Smart daughterboard has generated a request to send. The card is transmitting to a Smart device. XMIT/RECV (Yellow) (DS2) Data transmission in either direction. Flickering shows data flow. INPUT SELECT 3 (Yellow) (DS3) The daughterboard is communicating with the third I/O point on the FIC. INPUT SELECT 2 (YELLOW) (DS4) The daughterboard is communicating with the second FIC I/O point. INPUT SELECT1 (DS5) The daughterboard is communicating with the first I/O point on the FIC. Figure 5.1.24. Analog FIC W/Smart Transmitter Daughterboard LEDs RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-37 Analog FIC W/Smart Transmitter Daughterboard Jumpers The jumpers are on the Analog FIC. See Figure 5.1.20 and Figure 5.1.21 and Table 5.1.11 for jumper locations and settings. NOTE: Jumpers HD2 (output action) and HD4 (redundancy) may be covered by the Smart Transmitter Daughterboard. Changing these jumpers requires removal of the daughterboard. See below for daughterboard removal and replacement procedures. Analog FIC W/Smart Transmitter Daughterboard Fuses The fuses are on the Analog FIC. See Figure 5.1.22 and Table 5.1.12 for fuse locations and data. There are no fuses on the Smart Transmitter Daughterboard. Smart Transmitter Daughterboard Kit A Smart Transmitter Daughterboard Kit (1984--2483--000x) may be installed on a 1984--2518--0002 Analog FIC. For EMC compliance, a Smart Transmitter Daughterboard Kit (10P54500005) may be installed on a 10P54440002 Analog FIC. The kit is marked “SMART TRANSMITTER OPTION” on the PWA. NOTE: Upgrade of a 1984--2518--0001 Analog FIC requires assistance from FRSI System Support. The Analog FIC supports communications between the Smart transmitter and MultiPurpose Controller Processor when a Smart daughterboard is attached. The Smart daughterboard allows the system to communicate to a Smart device by sending digital information on top of the 4--20 mA signal. Smart Transmitter digital communication also requires I/O block reconfiguration. Refer to the I/O Block Configuration Manual (IO) for information. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-38 Smart Transmitter Daughterboard Installation This is the procedure for installing a Smart Transmitter daughterboard to an Analog FIC for Smart transmitter communications. The FIC being upgraded must be removed from the system for upgrade. This allows personnel with maintenance training and responsibility for the system to add hardware to upgrade an existing 4--20 mA FIC for Smart Transmitter digital communications. It does not have instructions for system software upgrades that may be necessary for Smart Transmitter communications. Use antistatic wrist straps whenever you handle circuit cards, be sure to transport cards in antistatic bags or boxes, and use an antistatic work surface when you fasten the Smart daughterboard to the FIC. Static discharge can damage the electronic circuitry, resulting in immediate or delayed adverse effects on performance. Do not remove the screws on the daughterboard side. The standoffs should remain with the daughterboard and these screws secured with a thread sealant when you separate a daughterboard from an FIC. Materials needed: D D D 01984--2518--0002 or 10P54440002 4--20 mA Field Interface card (FIC) 01984--2483--0005 or 10P54500005 Smart Transmitter Daughterboard #1 Phillips screwdriver NOTE: Use the 01984--2483--0005 Smart Transmitter Daughterboard with the 01984--2518--0002 FIC OR use the EMC-compliant 10P54500005 Smart Transmitter Daughterboard with the EMC-compliant 10P54440002 FIC. - To install a Smart Transmitter Daughterboard: 1. Take the FIC to be upgraded out of service. Do this while the plant is not running, or with I/O redundancy active, or with the output block in OVERRIDE with an Output Bypass card operating and the inputs in MANUAL mode. If a system software upgrade is needed, make all changes during a shutdown. 2. Remove the FIC from the Analog Card Cage and place the card in an antistatic bag or box for transport to the work area. 3. Lay the FIC flat on the work surface. At this time, check that all FIC jumpers are in the correct position. On some early FICs, some jumpers are difficult to change without removing the Smart daughterboard. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-39 4. Unpack the Smart daughterboard carefully to avoid bending components and connector pins. Remove protective packaging near two-pin connectors, if any. Remove screws (if installed) from the exposed ends of the five stand-offs, and save them. 5. Orient the Smart daughterboard components over the FIC with LEDs at the same end. Position the 20 pins on the Smart daughterboard over the 20 position socket on the FIC. These sockets and pins are just behind the LEDs on both cards. Do not push the pins into the sockets at this time. 6. Align all six pins in the three two-pin connectors at the other end of the Smart daughterboard over the three two-position sockets on the FIC. It may be necessary to straighten some pins slightly to align pins and sockets. 7. Carefully push the Smart daughterboard down evenly until the five standoffs rest on the FIC. 8. While holding the two cards together lightly, turn them over so that the assembly rests on the Smart daughterboard. 9. Check that the five standoffs line up with holes in the FIC. If not, check that all pins are in sockets. If the pins are correctly positioned, check to make sure that the pins are straight. 10. Start each screw into the standoffs. Tighten the screws securely. From point of initial contact to full tightness is approximately 1/4 turn. 11. Reinstall the FIC/Smart daughterboard combination in the Analog Card Cage. Be sure that the top and bottom edges of the FIC are in the card guides to avoid brushing the assembly against powered cards already in the cage. 12. After the FIC passes power-up diagnostics, it should immediately perform all the functions it had before the upgrade. It will not be able to perform Smart Transmitter digital communication until the correct software is running in the Controller Processor and FIC. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-40 Smart Transmitter Daughterboard LEDs Figure 5.1.25 shows the LEDs on the Smart Transmitter Daughterboard. Y Y Y Y Y RTS REQUEST The Smart daughterboard has generated a request to send. The card is transmitting to a Smart device. TO SEND Indicates data transmission in either direction. Flickering XMIT/RECV indicates data flow. INPUT SELECT 3 The daughterboard is communicating with the third I/O point on the FIC. INPUT SELECT 2 The daughterboard is communicating with the second I/O point on the FIC. INPUT SELECT 1 The daughterboard is communicating with the first I/O point on the FIC. Figure 5.1.25. Analog FIC Smart Transmitter Daughterboard LEDs RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-41 Pulse I/O FIC The Pulse I/O Field Interface Card (1984--2546--000x or EMC-compliant 10P54470002) can be used in any slot of an Analog Card Cage. The Pulse I/O FIC accepts a field pulse input and generates pulses of the specified width, frequency, or total count for output to the field. The card accepts two pulse inputs and provides for one output. The Pulse I/O FIC connects to a MultiPurpose Controller Processor (MPC). The input/output point is configured as a PIOB (Pulse I/O Block). The card is marked “PULSE I/O” on the PWA. Pulse devices vary widely in their specifications. It may be necessary to add signal conditioning, DC blocking, or filtering to the pulse input circuit. Refer to the material on the Auxiliary Terminal Block (1984--1543--000x) for suggestions. Table 5.1.13 lists the pulse and contact input FIC specifications. Table 5.1.13. Pulse I/O FIC Input Specifications Term Voltage Input Specification Contact Input Specification Input Frequency Sine wave 1 Hz -- 50 kHz Square wave .002 Hz -- 50 kHz .002 Hz -- 50 kHz Input Accuracy 0.05% of reading 0.05% of reading Resolution 0.01% of reading 0.01% of reading Count Match Response Time 5 ms maximum 5 ms maximum Minimum Pulse Width 10 ms 10 ms Voltage Range 50 mV to 30 V peak-to-peak -- ON State Current -- 9 mA minimum OFF State Current -- 5 mA maximum Short Circuit Current -- 20 mA nominal Open Circuit Voltage -- 21 V minimum, 24 V maximum Impedance 100 K ohms minimum 300 pF maximum -- Temperature Effect 0.01% within 0° to 50° C 0.01% within 0° to 50° C Common Mode Rejection 80DB 47--52, 57--63 Hz, at 3 V peak-to-peak -- Normal Mode Protection Fuse and transient suppressors -- Isolation Point-to-point point-to-point RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-42 Table 5.1.14 lists the pulse and analog output FIC specifications. Table 5.1.14. Pulse I/O FIC Output Specifications Term Pulse Output Specification Analog Output Specification Output Range 0 to 1 kHz 0--60 mA Output Accuracy -- 0.5% of 4--20 mA span below 20 mA, 0.4% of reading above 20 mA OFF State Leakage Current 20 mA maximum 20 mA maximum Output Current Limit 20 +/--0.5 mA 60 mA minimum 65 mA maximum Source Resistance 100 ohms maximum 25 ohms maximum (supply mode) Open Loop Voltage 21--24 V 21.5 V to 24.5 V Output Resolution -- 11 bits 4--20 mA range on 7.5 mA Output Fail Options None Off only Timing Accuracy +/--[ 20 ms + 0.01% of interval] -- Timing Resolution 1 msec -- Minimum Pulse Width 0.5 msec -- Maximum Frequency 1 kHz with one output point -- Temperature Effect 0.01%, within 0° to 50° C on timing 0.1% of 4--20 mA span, within 0° to 50° C on output current Isolation point-to-point point-to-point RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-43 Pulse I/O FIC LEDs Figure 5.1.26 shows the Pulse I/O FIC LEDs. LEDs G R Y R CARD GOOD (DS1) No card faults are detected and the Controller Processor card is controlling the output current. Blinking LED indicates the FIC is not connected to the field I/O. CARD FAULT (DS2) A card fault is detected or communications with the Controller Processor card have ceased. TX ENABLE (DS3) Indicates communications activity. The signal that enables the transmit signal from the Field Interface card to the Controller Processor card is active. 30 V FUSE BLOWN (DS4) Power fuse F1 has blown. This LED does not indicate the status of the fuses in the I/O loops. STATUS 1 (DS5) Represents the state of INPUT 1. (Note: the state is shown after the prescaler) STATUS 2 (DS6) Represents the state of INPUT 2. (Note: the state is shown after the prescaler) NOT USED For future use. Y Y Y Figure 5.1.26. Pulse I/O FIC LEDs RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-44 Pulse I/O FIC Jumpers Figure 5.1.27 shows the Pulse I/O Field Interface card jumper locations. Table 5.1.15 shows the jumper positions. All jumpers must be set to the same position. F11 F12 F21 F22 1--7 1--1 F31 1 2 3 F32 F1 HD4A, HD4B, HD4C Figure 5.1.27. Pulse I/O FIC Card Fuse and Jumper Locations Table 5.1.15. Pulse I/O FIC Card Jumper Positions RS3: Serial and Analog I/O Jumper 1:7, 1:3, or No Redundancy 1:1 Redundancy HD4A HD4B HD4C 1--2 2--3 Analog Card Cage SV: 5-1-45 Pulse I/O FIC Fuses Figure 5.1.27 shows the Pulse I/O FIC fuse locations. Table 5.1.16 gives fuse data. Table 5.1.16. Pulse I/O Field Interface Card Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G50382--0021 -- -- 273002 MSF 034.4224 2.0 A 125 V Plug-In F11 F12 F21 F22 F31 F32 G50382--0011 -- -- 273.250 MSF 034.4213 1/4 A 125 V Plug-In RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-46 Temperature Input FIC The Temperature Input FIC (1984--2731--000x) is marked “SIO, RTD/TC” on the PWA. It is also known as the “TC/RTD FIC”. The card can be used in any slot in an Analog Card Cage. The Temperature Input FIC accepts a temperature sensor input signal and converts it to a temperature value. The Temperature Input FIC can be used with a 3-wire resistance temperature device or with a thermocouple. Each of two Temperature Input FIC channels can be configured to support Resistance Temperature Detector (RTD), thermocouple, or cold junction compensator RTD. One cold junction compensator channel can be used to provide cold junction compensation for all thermocouple inputs used in an Analog Card Cage. The cold junction compensator sensor and thermal equalizer plate are attached to the marshaling panel. The input point is configured as a TIB (Temperature Input Block). NOTE: If the sensor circuit is disconnected and reconnected, the reading will be inaccurate for approximately 20 minutes. The reading will be within 1% in one minute and then gradually gain accuracy. This is a characteristic of the circuitry used. Figure 5.1.28 shows the Temperature Input FIC functional diagram. Table 5.1.17 lists the Temperature Input FIC specifications. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-47 Processor System Redundancy Jumpers I/O Card To Transfer Card Isolation Redundancy Circuitry Relay Drive RS-422 Comm Lines Serial Data To D/A Channel 1 Battery Backed Ram 8k Bytes 2K EPROM 229 Microamp Source (RTD Only) Flying Capacitor Input TC Transient Suppression N.C. 229 Microamp Source (RTD Only) 30 V Bus A 30 V Bus B SEL 1 DS4 SEL 2 128 Byte RAM Transient Suppression Channel 2 5V 5V (ISO) For Inputs 1&2 68701 Micro Flying Capacitor Input RTD Wd & Power Up/ Down Reset Timer 5V Regulator Dual Pulse Input INPUT 1 Signal Conditioning & Limiting Sensor Break Detect Analog To Dual Pulse Converter 5V Ref INPUT 2 Signal Conditioning & Limiting Sensor Break Detect SEL 2 SEL 2 Analog To Dual Pulse Converter 5V Ref Figure 5.1.28. Temperature Input FIC Functional Diagram RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-48 Table 5.1.17. Temperature Input FIC Specifications Term Specification Temperature Drift ±.125% Full Scale/25° C change from calibration temperature Cold Junction Compensation RTD 57.72 ohms nickel sensor value broadcast through Controller Processor Cold Junction Temperature Range --30 C to +70° C Accuracy Cold Junction Compensation Circuit ±.55° C Input Isolation point-to-point Maximum Sensor Wiring Resistance 500 ohms per line RFI Immunity .2% to .6% Full Scale External Resistance 3.21 to 390 ohms Ambient Cabinet Temperature 0--50° C Input Power 16--36 VDC Power Requirements 35 V 100 mA, nominal 30 V 112 mA, nominal 24 V 140 mA, nominal 20 V 164 mA, nominal Turn On Voltage 20 V, nominal Turn Off Voltage 15 V, nominal RTD Excitation Current 229 mA, nominal RTD Resistance Range Range 1: 0--100 ohms Range 2: 0--400 ohms Millivolt Input Range Gain 1: --4 to 22 mV Gain 2: --16 to 88 mV Accuracy (at calibration temperature) TC/mV, Range 1: ±0.075% (19.5 mV) TC/mV, Range 2: ±0.048% (50 mV) RTD/ohms, Range 1: ±150 Milliohms RTD/ohms, Range 2: ±200 Milliohms Input Impedance for Thermocouples >100 Megohm Use of a Temperature Input FIC requires you to configure the field wiring terminations for an RTD application, a thermocouple application, or a cold junction compensator RTD application. Field wiring is terminated on the Analog Marshaling Panel. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-49 An RTD sensor requires field wiring of the Analog Marshaling Panel to the Temperature Input FIC. If you use an external resistor to improve the RTD resolution, the external resistor also requires termination of the field wiring. Figure 5.1.29 shows the field wiring terminations for a Temperature Input FIC configured for a 3-wire RTD application. NOTE: A 4-wire RTD must be converted to a 3-wire RTD for proper connection. The fourth wire may be removed or coiled and secured at the RTD. Do not connect the fourth wire in parallel with the other wire. 101 A B 102 A B 101 C 102 C 201 A B 202 A 201 202 C C B Remove fourth wire 3-wire RTD 4-wire RTD Figure 5.1.29. Field Wiring Terminations for a Temperature Input FIC Configured for a 3-wire RTD Application Figure 5.1.30 shows the field wiring terminations for a Temperature Input FIC configured for an RTD application with external resistance. 101 A B 102 A B 101 C 102 C 201 A B 202 A B 201 202 C C External resistor RTD Figure 5.1.30. Field Wiring Terminations for an RTD Application with External Resistance A thermocouple sensor, and the cold junction compensator RTD to which it is linked, require field wiring of the Analog Marshaling Panel to the Temperature Input FIC. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-50 A cold junction compensator RTD for use with a thermocouple requires an FRSI supplied cold junction compensator RTD board mounted to the Analog Marshaling Panel. The cold junction compensator RTD is wired as an RTD. FRSI recommends that each cold junction compensator RTD be connected to its own Analog Marshaling Panel. However, a common cold junction compensator RTD may be connected to numerous marshaling panels with a minimal temperature difference, if the marshaling panels are located close to the thermocouples to which the cold junction compensator RTDs are linked. Figure 5.1.31 shows the field wiring terminations for a Temperature Input FIC configured for a thermocouple application using a cold junction compensator RTD. 101 A B 102 A 101 102 B C C 201 A B 202 A 201 202 B C C CJC RTD Thermocouple Thermocouple Thermocouple Figure 5.1.31. Field Wiring Terminations for a Thermocouple and Cold Junction Compensator RTD Application A Temperature Input FIC can be used as a redundant FIC to back up any combination of RTDs, thermocouples, or cold junction compensator RTDs as long as the ranges that it is backing up have been calibrated. Refer to Chapter 8, Calibration, for information about calibrating a Temperature Input FIC. The Temperature Input FIC supports 1:1, 1:3, or 1:7 redundancy. Upon switchover from a failed Temperature Input FIC to the redundant FIC, the hold forward flag is asserted for approximately 5 seconds or until the A/D converter on the FIC is stable. This holds the input temperature stable while the switchover occurs. For 1:3 or 1:7 redundancy, the input terminal for the Redundant Input/Output Block (RIOB) must not have any wiring connected to the FIC. For 1:1 redundancy, the RIOB must have all input terminals connected in parallel with the TIB. Use the same wire type as is used to connect the FIC. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-51 Temperature Input FIC LEDs Figure 5.1.32 shows the LEDs on the Temperature Input FIC. G R Y R CARD GOOD (DS1) No card faults are detected. CARD FAULT (DS2) A card fault is detected or communications with the Controller Processor card have ceased. TX ENABLE (DS3) 30 V FUSE BLOWN (DS4) Indicates communications activity. The signal that enables the transmit signal from the Field Interface Card to the Controller Processor is active. Power Fuse F1 has blown. Figure 5.1.32. Temperature Input FIC LEDs RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-52 Temperature Input FIC Jumpers The redundancy scheme jumpers indicate how the redundant Field Interface cards are configured. The proper hardware and software must be present to have FIC redundancy. Figure 5.1.33 shows redundancy scheme jumper positions. Table 5.1.18 gives jumper values. All three sets of jumpers must be in either the upper or lower position for proper operation. HD2 HD3 HD4 1 2 3 Other 1:1 Redundancy F11 F9 F10 F6 F7 F1 F8 Figure 5.1.33. Temperature Input FIC Fuse and Jumper Positions Table 5.1.18. Temperature Input FIC Card Jumper Positions RS3: Serial and Analog I/O Jumper 1:7, 1:3, or No Redundancy 1:1 Redundancy HD2 HD3 HD4 1--2 2--3 Analog Card Cage SV: 5-1-53 Temperature Input FIC Fuses Figure 5.1.33 shows the locations of the fuses on the Temperature Input FIC. Table 5.1.19 gives fuse data. Table 5.1.19. Temperature Input Field Interface Card Fuses Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G50382--0021 273002 MSF 034.4224 2.0 A 125 V Plug-In F6 to F11 G50382--0009 273.125 MSF 034.4210 1/8 A 125 V Plug-In Analog Extender Card An Analog Extender card (1984--2461--000x) may be used to move cards out of the Analog Card Cage for easier access. It is marked “FIC 2--IN 1--OUT/COMM EXTENDER BD” on the PWA. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-54 Analog Marshaling Panel The Analog Marshaling Panel provides connection of field wiring to the Analog Card Cage. Analog Marshaling Panels exist in several versions with different markings on the PWA. Aside from EMC compliance and mounting differences, they are functionally identical. D D D D 1984--2415--0001 marked “MULTISTRATEGY MARSHALLING PANEL” near the part number on the PWA. This Marshaling Panel is EMC compliant. 10P54590001 European Analog Marshalling Panel (without fuses) and 10P54620001 European Analog Marshalling Panel (with fuses). These two Marshaling Panels are EMC compliant. 1984--2512--000x marked “MULTISTRATEGY MARSHALLING PANEL” near the part number on the PWA. 1984--2448--000x marked “ANALOG MARSHALLING PANEL” near the part number on the PWA. The label at the top of the panel may show either: D “SERIAL MARSHALLING PANEL” D “MPC MARSHALLING PANEL” Shield connections are made to the SHIELDS terminals. A multipin connector serves to connect the Analog Marshaling Panel to the Analog Card Cage. Labels are provided to show examples of wiring different devices and to record the details of field wiring connections. Refer to the Site Preparation and Installation Manual (SP) for detailed mounting, cabling, and field wiring examples; including EMC compliance requirements. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-55 Figure 5.1.34 shows Analog Marshaling Panel: 1984--2415--0001. Figure 5.1.35 shows European Analog Marshaling Panel 10P54620001 (with fuses). Table 5.1.20 shows fuse data for European Analog Marshaling Panel 10P54620001. Figure 5.1.34. Analog Marshaling Panel 1984--2415--0001 Fuses Figure 5.1.35. European Analog Marshaling Panel 10P54620001 Table 5.1.20. European Analog Marshaling Panel 10P54620001 Fuses Fuse FRSI Part No. Characteristics F1 to F24 G53394--0250--0005 0.25 A 125 V IEC 127--2 Fast Acting 5 x 20 mm RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-56 Figure 5.1.36 shows Analog Marshaling Panel 1984--2512--0001. 01984--2512--0001 101 102 101 102 201 202 201 202 301 302 301302 401 402 401 402 101 102 103 201 202 301 302 303 401 402 403 A B A B C C A B A B C C A B A B C C A B A B C C Å 203 MPC Marshalling panel A B A B A B A B A B A B A B A B A B A B A B A B TB3 TB1 J946 SHIELDS Field Devices INPUTS To I/O Card Cage -- A B 4--20 : SYS PWR -- + 4--20 : RMT PWR + V + -- 1 -- 5 VOLT V+ V-- PULSE OUTPUTS (1 -- 8) 4 -- 20 F+ F-A B -+ Field Valve + T -- -T + Self Powered Transmitter System Powered Transmitter SHIELDS Å TB2 TB4 501 502 501 502 601 602 601 602 701 702 701702 801 802 801 802 501 502 503 601 502 503 701 702 703 801 802 803 A B A B C C A B A B C C A B A B C C A B A B C C CONTROL FILE NODE A B A B A B A B A B A B A B A B A B A B A B A B CONTROLLER SLOT FLEXTERM Figure 5.1.36. Analog Marshaling Panel 1984--2512--0001 RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-57 Cold Junction Compensator A Cold Junction Compensator (1984--2616--000x) is used with thermocouples. It carries a label (1984--2618--000x) that shows the connections to be used for various applications. It mounts firmly against the metal in the center of the Analog Marshaling Panel to sense the ambient temperature at the Analog Marshaling Panel. There are no replaceable parts in the Cold Junction Compensator. Marshaling Panel Auxiliary Terminal Block The Marshaling Panel Auxiliary Terminal Block (1984--1543--000x) provides a method of connecting external components into the control loop. Figure 5.1.37 shows the Marshaling Panel Auxiliary Terminal Block. Clamp Screws (6 total) Field Device or Component Termination Points (6 Total) Analog Marshalling Panel Terminal Support Standoff Figure 5.1.37. Marshaling Panel Auxiliary Terminal Block NOTE: The terminal block may be mounted to either the upper or lower row of terminals on the Analog Marshaling Panel. The block is marked with normal and inverted letters; use the set that is right side up for your connections. RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-58 If a Cold Junction Compensator is in place, the screw and standoff at the bottom of the block should be removed to provide clearance for the cold junction compensator plate. The Auxiliary Terminal Block has six field device or component termination points and an A and B connection point for the Analog Marshaling Panel. The termination points are connected in pairs and there are no active components. The layout is designed to meet CSA 250V spacings for a PWB without transient limiting. The Auxiliary Terminal block is also CSA approved for 300V and accepts 14 AWG wire. The electrical diagram is shown in Figure 5.1.38. Values of components connected will vary with specific applications. Field Device or Component Termination Points Marshaling Panel Connection Fingers NOTE: Observe the “A” and “B” Terminal Labels When Connecting Components. Figure 5.1.38. Auxiliary Terminal Block Wiring Diagram Figure 5.1.39 shows a method of resolving self- or system-powered jumper conflicts when implementing 3--1 or 7--1 redundancy. A 27 volt Zener diode in series with a system-powered input will accept a 4--20 mA signal from a self-powered transmitter. This approach must be used carefully. B Input with “Sys Pwr” Jumper Set A NOTE: Observe the “A” and “B” terminal labels when connecting components. Self Powered XMTR -- Self Powered XMTR + Figure 5.1.39. 4--20 mA Application -- Redundancy Loop Power Mismatch RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-59 Figure 5.1.40 shows the Auxiliary Terminal Block which is used when a separate power supply and monitoring device are required in series with the 4--20 mA current loop and transmitter. Loop continuity is preserved even if the FIC fails or is removed. The Auxiliary Terminal Block allows wiring to such a device without supplying separate rail mounted terminal blocks. B Supply and Monitor -Supply and Monitor + Input XMTR + (Loop Powered) NOTE: Observe the “A” and “B” terminal labels when connecting components. A XMTR -- Figure 5.1.40. 4--20 mA Input Application -- External Supply and Constant Loop Continuity The Auxiliary Terminal Block can also be used to connect current meter leads and Field calibrator leads. Figure 5.1.41 to Figure 5.1.43 show some applications of the Auxiliary Terminal Block in Pulse I/O. The need may arise to install external components in order to perform signal level translation, attenuation, or filtering. This is due to the wide variety of devices and signal levels encountered in pulse I/O. B Pulse -- Pulse + NOTE: Observe the “A” and “B” terminal labels when connecting components. A Figure 5.1.41. Pulse Application -- Simple DC Block RS3: Serial and Analog I/O Analog Card Cage SV: 5-1-60 Figure 5.1.42 shows the addition of a loading resistor to the blocking capacitor. B NOTE: Observe the “A” and “B” terminal labels when connecting components. Pulse -- Pulse + A Figure 5.1.42. Pulse Application -- DC Block/Load B NOTE: Observe the “A” and “B” terminal labels when connecting components. Pulse -- Pulse + A Figure 5.1.43. Pulse Application -- Low Pass Filter RS3: Serial and Analog I/O Analog Card Cage SV: 5-2-1 Section 2: Contact Card Cage This section covers the: D Contact Card Cage D Contact FlexTerm D Contact Termination Boards D Contact Marshaling Panels D Opto-Isolators D Discrete Switch Panel D Contact Field Interface cards D Contact Extender card RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-2 Contact Card Cage and Contact FlexTerm The MultiPurpose Controller (MPC) Contact Card Cage (also known as the MPC Contact FlexTerm) and the superseded Contact FlexTerm each may contain eight Contact Field Interface cards to control 48 modules for field interface. A ControlFile MPC Controller Processor or Contact Controller Processor can control 96 modules on two Contact Card Cages or on two Contact FlexTerms connected together. Each Contact Card Cage or Contact FlexTerm can hold two 1984--1288--000x Contact Field Termination cards which contain field wiring terminals for 24 points and up to 24 input or output solid state switch modules. There are three different Contact FlexTerm and Contact Card Cage assemblies with different capabilities. Table 5.2.1 compares the features of each of these assemblies. Table 5.2.2 shows parts replacement data. Table 5.2.1. Comparison of Contact Card Cage and Contact FlexTerm Assemblies Capability Contact Card Cage 1984--2576--0001 Contact FlexTerm 1984--1175--000x Contact FlexTerm 1984--1336--000x Printed Wiring Assembly (PWA) Marking MPC CONTACT FLEXTERM MOTHERBOARD CONTACT FLEXTERM MOTHERBOARD II CONTACT FLEXTERM MOTHERBOARD Marshaling Panel Connectors Yes Yes No 2 Controller Communication Connectors with redundancy jumpers Yes Yes No Image MPC CC CC Cage A/B jumpers Yes No No Local I/O modules Yes No No Connector bottom for cage jumpering Yes Yes Yes Connectors for contact switch panels Yes Yes Yes Fuse board for powering switch panel Yes Yes Yes RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-3 Table 5.2.2. Parts Replacement Part No. Replaces Characteristics 1984--2576--0001 None Used only with MPCx images 1984--1336--000x None Used only with CC image. 1984--1175--000x 1984--1336--000x Used only with CC image. Has marshaling panel connectors Contact input/output modules are mounted on two panels with field wiring fuses and terminal strips. Modules are color-coded according to module type. The contact modules have internal isolation so that no electrical connection is made between the system circuits and the field wiring. Label and legend stickers attached to the motherboard and cabinet doors describe module, fuse, and terminal strip assignments. The fuse card only protects the power to the manual switch station connectors. Optional contact switch panels can be used to manually set discrete contact outputs to ON, OFF, or AUTO. Each panel is equipped with six three-way switches and System Normal and System Fail indicators. A Contact Card Cage can be cabled only to a ControlFile MPC Controller card (1984--2500--000x) loaded with the MPC image. A Contact FlexTerm can be cabled to a ControlFile MPC Controller card (1984--2500--000x) loaded with the standard CC image or to a Contact Controller card (1984--1374--000x or 1984--1445--000x) with the standard CC image. NOTE: You cannot cable a Contact Card Cage and a Contact FlexTerm to the same Controller card. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-4 Contact Card Cage The Contact Card Cage (1984--2576--0001) is marked “MPC CONTACT FLEXTERM MOTHERBOARD” on the PWA. A Contact Card Cage can be cabled only to a ControlFile MPC Controller card (1984--2500--000x) loaded with the MPC image. Figure 5.2.1 shows a Contact Card Cage. It has cage address jumpers to select either Cage A or Cage B and uses the MPC point addressing scheme. It also has Controller redundancy select jumpers. The 40-position connectors at the top are used to connect to another Contact Cage, an Analog Cage, and a Controller Processor or redundant Controller Processor. The 40-position connector at the bottom is not used with the Contact Card Cage. The Contact Card Cage has a connector for a Field Termination Board as well as for remote Contact Marshaling Panels. Fuse Card Field Termination Board Redundant Cable Connection Redundancy Jumpers Power Connector Field Termination Board FICs Marshaling Panel Cable Connection Address Jumpers Figure 5.2.1. Contact Card Cage RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-5 Contact Card Cage FIC Addressing Figure 5.2.2 shows the addressing scheme for Contact Card Cage Field Interface Cards (FICs). The FIC in the first slot addresses points 101 through 106, the one in the second slot addresses points 201 through 206, etc. The left hand Termination Board addresses points 101 through 406, which are controlled by the upper set of FICs. The right hand Termination Board addresses points 501 through 806, which are controlled by the lower set of FICs. 501 101 201 301 401 101 106 206 306 406 501 601 701 801 806 506 606 706 806 406 Figure 5.2.2. FIC Addressing in a Contact Card Cage RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-6 Contact Card Cage Wiring The Contact Card Cage may be wired to field points either with a Termination Board or a Marshaling Panel. Each accommodates 24 field I/O terminations. The Termination Board plugs directly into the Contact Card Cage motherboard left or right position, depending on the addresses served. Similarly, the Marshaling Panel connects by the appropriate connector on the motherboard. Figure 5.2.3 shows the connection of a Marshaling Panel serving points 501 through 806. Cable Between Card Cage and Marshaling Panel Optional Marshaling Panel Field Termination Board Fuses OPTO Isolators Fuses Terminal Strips Figure 5.2.3. Contact Card Cage Wiring Example RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-7 Contact FlexTerm The Contact FlexTerm II (1984--1175--000x) is marked “CONTACT FLEXTERM MOTHERBOARD II” on the PWA. It is used with the Contact Controller Processor or the MPC Controller Processor running the Contact Controller (CC) program. The I/O points are numbered 1--96. This assembly has connectors for remote Contact Marshaling Panels and Controller redundancy select jumpers. The two 40-position connectors at the top connect to the Contact Controller and the optional redundant Contact Controller only. This Contact FlexTerm serves points 1--48. The 40-position connector at the bottom connects only to another Contact FlexTerm that would serve points 49--96. Figure 5.2.4 shows the Contact FlexTerm. 1 2 3 6 7 4 No. 5 Description 8 No. Description 1 Power Plug 5 To Marshaling Panel 1 2 Fuse Panel 6 To Marshaling Panel 12 3 Cable to ControlFile 7 Contact Termination Board 2 4 Contact Termination Board 1 8 To Second Contact FlexTerm Figure 5.2.4. Contact FlexTerm The earlier Contact FlexTerm (1984--1336--000x) is marked “CONTACT FLEXTERM MOTHERBOARD” on the PWA. It is like the 1984--1175--000x except that it does not have marshaling panel connectors or Controller redundancy jumpers and has only one 40-position connector to go to a Contact Controller. A Contact FlexTerm may be cabled to a ControlFile MPC Controller card (1984--2500--000x) loaded with the standard CC image or to a Contact Controller card (1984--1374--000x or 1984--1445--000x) with the standard CC image. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-8 Contact FlexTerm FIC Addressing Figure 5.2.5 shows the contact I/O points controlled by each FIC and connected by the Contact Termination Boards. 25 13 19 1 7 6 12 18 24 1 25 31 37 43 48 30 36 42 48 24 Figure 5.2.5. FIC Addressing in Contact FlexTerms Contact FlexTerm Wiring A Contact FlexTerm may contain eight Contact Field Interface cards and connect 48 OPTO modules for field interface points. A Contact Control Processor can control 96 modules on two Contact FlexTerms. Contact FlexTerms are connected together by cabling between the bottom plug of the first FlexTerm, and the top of the second. Figure 5.2.6 shows wiring for two Contact FlexTerms connected together to serve 96 contact points. The Field Interface cards are paired up so that the first communication line talks to cards 1 and 2, the second communication line talks to cards 3 and 4, and so on. Communication lines 5 through 8 go to the lower cage. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-9 25 1 Wire Channel Cable Ties 48 First Contact FlexTerm Containing Termination Points 1 Through 48 Terminal Strips 24 73 Second Contact FlexTerm Containing Termination Points 49 Through 96 Figure 5.2.6. Contact FlexTerm Field Wiring RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-10 Contact Card Cage and Contact FlexTerm Jumpers The Contact Card Cage and Contact FlexTerm motherboards have jumpers for card cage addressing and for redundancy. The older Contact FlexTerm (1984--1336--000x) does not have redundancy jumpers. The redundancy jumpers indicate whether or not redundant Controller Processors are connected to the Contact Card Cage in the ControlFile. Figure 5.2.7 shows the jumper locations on the motherboard. Table 5.2.3 shows the jumper positions. Address Jumpers HD3A through HD3D Redundancy Jumpers HD1 and HD2 Address Jumpers HD3E through HD3H Figure 5.2.7. Contact Card Cage and Contact FlexTerm Jumper Locations Table 5.2.3. Contact Card Cage and Contact FlexTerm Jumper Positions Jumper Purpose Position HD1 HD2 Indicates whether redundant Controller Processor Cards are connected to the Contact Card Cage and the ControlFile. NORMAL: No redundant Controller Processors REDUNDANT: Redundant Controller Processors (HD1 and HD2 must be jumpered in the same position.) HD3A through HD3H Indicates whether the Contact Card Cage is Card Cage A or Card Cage B. The eight sets of jumpers correspond to the eight contact FICs. RS3: Serial and Analog I/O Card Cage A Card Cage B Indicates Card Cage A Indicates Card Cage B (HD3A through HD3H must be jumpered in the same position.) Contact Card Cage SV: 5-2-11 The Remote Marshaling Connectors Label indicates the Contact Card Cage address, A or B, and its corresponding I/O point addresses. This label is for information only. When the card cage address jumpers are positioned, write an “X” in the appropriate box to track the cage jumpering location. Figure 5.2.8 shows the Remote Marshaling Connectors Label and markings. “X” Indicates Cage A is Jumpered. J425 FIC I/O Point Addresses: A101--A406 J426 FIC I/O Point Addresses: A501--A806 “X” Indicates Cage B is Jumpered. J425 FIC I/O Point Addresses: B101--b406 J426 Fic I/O Point Addresses: B501--B806 Remote Marshaling Connectors Remote Marshaling Connectors (Cage Jumpering A or B) (Cage Jumpering A or B) J425 A101-A406 X B101-B406 J426 J425 J426 A501-A806 A101-A406 A501-A806 B501-B806 Label B101-B406 X B501-B806 Figure 5.2.8. Remote Marshalling Connectors Label RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-12 Contact Card Cage and Contact FlexTerm Fuses A fuse panel (1984--1321--000x) is mounted at the top left hand side of the Card Cage or FlexTerm. Table 5.2.4 gives fuse data. Table 5.2.4. Contact Card Cage and Contact FlexTerm Fuses FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics G09140--0032 MDL 2 313002 2 A 250 V Slow Blow RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-13 Contact Termination Board The Contact Termination Board (1984--1288--000x) is marked “CONTACT FIELD TERMINATION” on the PWA and is also known as a “Local Field Termination Board”. The Contact Termination Board plugs directly into the motherboard connectors of a Contact Card Cage or a Contact FlexTerm. It accommodates 24 field I/O terminations. The Contact Termination Board provides optical isolation and fusing for each I/O point. The Contact Termination Board allows use of the 1 amp OPTO only. The fuses on the Termination Board are in line with the field wiring. Figure 5.2.9 shows the Contact Termination Board. NOTE: When installing a Contact Termination Board take particular care to be sure that both connectors are correctly inserted in the receiving slots. Fuse 101 Fuse 102 101 102 103 104 105 106 201 202 203 204 205 206 301 302 303 304 305 306 401 402 403 404 405 406 OPTOs Field wiring terminal strip Figure 5.2.9. Contact Termination Board RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-14 Contact Termination Board Wiring Figure 5.2.10 shows an example of field wiring using a Contact Termination Board. The wiring using a Contact Marshaling Panel is different. NOTE: The “+” and “--” terminals are reversed on the second Contact Termination Board. 1 2 + -- -- + + -- -- + 25 26 Figure 5.2.10. Contact FlexTerm Field Wiring Using a Contact Termination Board The system can power a Contact Termination Board by wiring in power from an external source. The power must be fused somewhere between the power supply and where it is connected to the Contact Termination board. Figure 5.2.11 shows an example of system powering. OPTO 1.5A OPTO 1.5A OPTO 1.5A OPTO 1.5A OPTO 1.5A OPTO 1.5A + Field wiring Figure 5.2.11. Contact FlexTerm System Power Wiring Using a Contact Termination Board RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-15 Contact Termination Board Fuses The Contact Termination Board provides fuses in line with the field wiring. Figure 5.2.9 shows the fuse locations. Table 5.2.5 gives fuse data. NOTE: Contact Termination Boards may have 4 amp fuses installed. The fuses should be sized to match the load. Table 5.2.5. Contact Termination Board Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics F1 to F24 G09140--0029 MDQ 1--1/2 -- -- 1.5 A 250 V Slow Blow NOTE: Other fuses may be used to match the applied load. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-16 Contact Marshaling Panel The Contact Marshaling Panel (1984--2459--000x) connects to the Contact Card Cage or Contact FlexTerm. Each Contact Marshaling Panel has 24 I/O points arranged in groups of six. Each group of 6 I/O points is served by a Contact Field Interface card in the card cage or FlexTerm. It is marked “CONTACT MARSHALLING PANEL” on the PWA. Figure 5.2.12 shows the Contact Marshaling Panel. AC or DC Input Voltage for Modules 101 -- 106 OPTO 1 VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo V1 N1 Ä Ä Ä Ä Ä 101 102 103 104 105 301 302 303 304 305 Å Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä V2 N2 Ä Ä 306 Ä 401 402 403 Ä Ä Ä 404 405 406 Ä Ä V4 Ä N4 N3 oooo oooo oooo + -- 106 201 202 203 204 205 206 CONTACT MARSHALLING PANEL CONTROL FILE NODE_________CONTROLLER SLOT_______ V3 V3+--N3 V3+--N3 Å Å Å Å oooo oooo V3+--N3 V3+--N3 V3+--N3 oooo V3+--N3 oooo oooo V4+--N4 V4+--N4 oooo V4+--N4 ROSEMOUNT INC 1986 CONTACT Marshalling PANEL PWA 01984--2459--0001 ___ SER____________ oooo oooo Å Å Å Å oooo V4+--N4 V4+--N4 V4+--N4 Jumper Figure 5.2.12. Contact Marshaling Panel The Contact Marshaling Panel provides field wiring termination strips, optical isolators, fuses, and address labels for field wiring. Optical Isolator Modules of up to 3 ampere capacity may be used with the Contact Marshaling Panel. Each group of 6 points is connected to a single contact FIC card as indicated by the highlighting in Figure 5.2.13. Each group of 6 points can be powered (i.e., system powered) from the appropriate terminal strip at the right side as shown in the figure. Table 5.2.6 lists the Contact Marshaling Panel specifications. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-17 Table 5.2.6. Contact Marshaling Panel Specifications Specification Term Current Ratings/Temperature (at panel) DC Output: 2.3 amps at 25° C 1.8 amps at 40° C 1.0 amps at 60° C AC Output: 3.0 amps at 25° C 2.3 amps at 40° C 1.2 amps at 60° C Voltage Maximum: 300V rms Fusing 4 amp slow blow per Optical Isolator Module Cabling 50 conductor round cable Maximum distance Card Cage or FlexTerm to Marshaling Panel: 230 m (750 feet) Connection to Card Cage or FlexTerm 50 conductor cable terminated to connector on motherboard Wire gauge 2.5--0.34 mm2 (14--22 AWG) solid or stranded Contact Marshaling Panel Wiring The Contact Marshaling Panel accommodates 24 field I/O terminations, with four contacts available at each point as shown in Figure 5.2.13. The (+) and the (--) connections are used for devices powered in the field. A jumper is required from Vx to + to provide system power to the point. Jumpers are shown in Figure 5.2.12 on points 305 and 403. The fuse is in series with the Vx power supply to the point. +Vx Vx Nx Module + -- Nx Figure 5.2.13. Contact Marshaling Panel Wiring Circuit RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-18 Figure 5.2.14 and Figure 5.2.15 show several examples of powering input devices. Bringing power to the V1 and N1 connections at the right of the panel provides power for the six points served by FIC 1 (101--106). Address 104 shows the recommended wiring hookup for system powering an input. Address 101 shows an alternate wiring hookup for system powering an input. Address 203 shows the recommended wiring hookup for remote powering an input. Address 205 shows an alternate wiring hookup for remote powering an output. NOTE: When you are using system power DC, you will need to use a commutating diode across the field wiring. A 1N4003 diode is often used. A good alternative is a P6KE36CA transient suppressor. AC or DC Remote Supply Input Powered From V1 (Alternate), and Load Powered From V1 + +V Input Powered From V1 (Recommended) + -OPTO 1 --V DC Remote Supply + -- See Note in Text on Use of Diode Commutating Diode Fuse Fuse AC or DC Input Voltage for Modules 101--106 -- VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 VI+-- N1 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 V2+-- N2 oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo oooo V1 N1 Ä Ä Ä Ä 101 102 103 104 Å AC or DC Input Ä Ä Ä Ä Ä Ä Ä Ä V2 N2 Å Å Å Å + -- 105 106 201 202 203 204 205 206 CONTACT MARSHALLING PANEL CONTROL FILE NODE_________CONTROLLER SLOT_______ AC or DC Input AC or DC Input DC Output AC or DC Input Voltage for Modules 201--206 Figure 5.2.14. Contact Marshaling Panel Field Wiring: Example 1 RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-19 CONTACT MARSHALLING PANEL CONTROL FILE NODE_________CONTROLLER SLOT_______ Å 301 302 303 304 305 306 401 402 403 404 405 406 V4 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä N4 V3 N3 oooo oooo V3+--N3 V3+--N3 oooo oooo V3+--N3 V3+--N3 V3+--N3 oooo oooo V3+--N3 oooo oooo V4+--N4 V4+--N4 oooo V4+--N4 ROSEMOUNT INC 1986 CONTACT Marshalling PANEL PWA 01984--2459--0001 ___ SER____________ AC Out oooo oooo Å Å Å Å + -+ -- oooo V4+--N4 V4+--N4 V4+--N4 DC Out Load (No diode required for AC) AC Voltage For Modules 301--306 DC Relay See Note In Text On Use Of Diode DC Voltage For Modules 401--406 Figure 5.2.15. Contact Marshaling Panel Field Wiring: Example 2 Contact Marshaling Panel Fuses Contact Marshaling Panel fuses are in line between the terminal block and the individual point (V1, 2, 3, or 4), not in the field wiring. Table 5.2.7 gives fuse data. This fuse size is for the maximum allowable load on the Optical Isolator Module. A smaller fuse may be used if a smaller load is applied. Table 5.2.7. Contact Marshalling Panel Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics F1 to F24 G09140--0038 MDL 4 313004 4 A 250 V Slow Blow NOTE: Smaller fuses should be used if smaller loads are applied. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-20 Optical Isolator Modules Optical Isolator Modules (G12243--00xx) are solid-state, optically isolated relays that define each contact point as an input or an output. Care must be taken to make sure that the proper type of modules are installed because input and output modules are mechanically interchangeable. Each module has a fuse in series with the field pair. Table 5.2.8 lists the module types currently available. Table 5.2.8. Optical Isolator Modules * Part Number C12243-- Model Function Output Contact* Voltage Color --0005 IAC5A Input None 180--280 VAC Yellow --0006 IDC5 Input None 10--32 VDC White --0007 IDC5B IDC5F Input None 4--16 VDC White --0008 IAC5 Input None 90--140 VAC Yellow --0009 ODC5 Output N.O. 5--60 VDC Red --0010 ODC5A Output N.O. 5--200 VDC Red --0011 OAC5A5 Output N.C. 24--280 VAC Black --0012 OAC5 Output N.O. 12--140 VAC Black --0013 OAC5--A OAC5--1 Output N.O. 24--280 VAC Black All output modules, except OAC5A5, have normally open (N.O.) outputs. The output contact is open when the block output is false. NOTE: AC inputs are yellow and outputs are black. DC inputs are white and outputs are red. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-21 The maximum current rating for modules depends on the location of the optical isolation modules. The maximum current rating for modules mounted on standard Contact Termination Boards (1984--1288--000x) is 1 amp. Table 5.2.9 lists the maximum current ratings for modules mounted on Contact Marshaling Panels (1984--2459--000x). Table 5.2.9. Maximum Current Ratings for Modules Mounted on Marshaling Panels RS3: Serial and Analog I/O Ambient Temperature DC Output Modules AC Output Modules 25° C 2.3 Amps 3.0 Amps 40° C 1.8 Amps 2.3 Amps 60° C 1.0 Amp 1.2 Amps Contact Card Cage SV: 5-2-22 Discrete Switch Panel A Discrete Switch Panel (1984--0360--000x) is available to allow bypassing a Contact FIC output. Figure 5.2.16 shows the Discrete Switch Panel. The panel provides 6 switches and LEDs to indicate the switch position (red -- open; green -- closed). The switch can also be placed in the center position, which allows the Contact FIC to operate normally. When in this position, the LEDs indicate the state of the point. The bottom red and green LEDs indicate the status of Controller Communication. If the green LED is on, the Controller is communicating with the Card Cage or FlexTerm. The Discrete Switch Panel plugs into the connectors on a Contact Card Cage or Contact FlexTerm, where there is a plug for each FIC, to bypass the Contact FIC output. Cable 1984--0361--00xx is used. OFF AUTO ON R G R G R G R G R G R G FAIL R NORM SYSTEM G Figure 5.2.16. Discrete Switch Panel RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-23 Contact Field Interface Cards The 1984--1460--000x and 1984--1304--000x Contact Field Interface cards interface with the Controller Processor to turn optical isolator output modules on and off. Contact FIC --1460 supersedes card --1304. Both cards perform the same function, but the --1304 works only with the CC image. The cards are marked “CONTACT I/O” on the PWA. The jumpers have the same effects on the outputs of both cards. Each Contact Field Interface card card can control six modules in any combination of input or output, AC or DC. Isolated voltage from the switching power regulator provides power for the isolated circuits on the communication line to the Controller Processor. Figure 5.2.17 shows a functional diagram of the Contact Field Interface card. The 6801 microprocessor with 2K of ROM and 128 bytes of RAM handles all communications and module write and feedback sense. A watchdog timer driven from the latch strobe line monitors the microprocessor for lack of activity and resets the microprocessor if it fails. As communications from the Controller Processor indicate the proper state of each output module, the microprocessor passes this information to the latch and pulses the strobe line. This line goes through a circuit that pulses the latch to clock the data through to the output circuit. The output circuit has 6 identical circuits. An 8 mA current source is turned on and off by the latch and goes through a sense resistor to the indicator LED and to the microprocessor in order to indicate if the current flow path through the output module is complete. In the case of input modules, the current source is turned on all the time by the latch. If the module has no input voltage to it, no current will flow, so no voltage will be seen across the sense resistor. If the module is on, the current path is completed through the module (and the indicator LED), causing a voltage drop across the sense resistor which indicates to the microprocessor that the module is on. The power regulator, in addition to providing isolated 5 V, also provides 5 V to the microprocessor and associated circuitry. +8 V is generated for the current source. Six additional input lines are provided to the microprocessor from the Manual Switch Station to indicate each output module that is manually bypassed. Table 5.2.10 lists the Contact FIC specifications. RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-24 30 V (A) +5 V +12 V Power Regulator +5 V Isolated 30 V (B) Isolated Return Return Hold Clear Typical (6 Circuits) Output WatchLatch dog +5 V Timer Strobe Q0 Receive Data Transmit Data Comm & Transmit Enable Isolation RS-422 Comm Lines +5 V +12 V Q6 Reset Optical Module IN 6801 Micro Processor Contact Switch Panel Sense Lines Micro OK Signal Figure 5.2.17. Contact FIC Functional Diagram Table 5.2.10. Contact FIC Specializations Item Specification Power: Voltage Current 22--34 VDC 90 mA at 30 V typical Switching current RS3: Serial and Analog I/O 10 mA typical, 8 mA minimum Contact Card Cage SV: 5-2-25 Contact FIC LEDs LEDs are used to indicate transmit enable, whether the card is good or bad, and the six output module states. Figure 5.2.18 shows the Contact Field Interface card LEDs. LEDs Y Y Y I/O 1--6 (DS5--DS10) Indicates the logic state of the module’s input or output. With a normally open input or output, the module is ON if the LED is ON. With a special order, normally-closed output module, contact is made with no power applied. The LED is ON with an open contact on the module. 30 V FUSE BLOWN (DS3) Replace power fuse F1 on the Contact Field Interface Card. Y Y Y R Y R G TX ENABLE (DS4) The signal that enables the transmit signal from the Field Interface Card to the Contact Processor is active. CARD FAULT A Fault is detected on the contact Field Interface card, or communications with the contact processor have ceased. (DS2) Discrete outputs will go to the condition called for by the position of jumper HD1 (hold or off). CARD GOOD No faults are detected on the Contact Field Interface card (DS1) and communication with the Contact Processor is active. Figure 5.2.18. Contact Field Interface Card LEDs RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-26 Contact FIC Jumpers Figure 5.2.19 shows the jumper locations on a 1984--1460--000x card. Figure 5.2.20 shows the jumper locations on a 1984--1304--000x card. HD1 F1 Figure 5.2.19. Contact FIC 1984--1460--000x Fuse and Jumper Locations HD1 F1 Figure 5.2.20. Contact FIC 1984--1304--000x Fuse and Jumper Location RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-27 Table 5.2.11 gives jumper values for both cards. Table 5.2.11. Contact Field Interface Card Jumper Positions Jumper Position Effect HD1 HOLD Hold output value on communications failure OFF Drive output to zero on communications failure Contact FIC Fuses Figure 5.2.19 shows the fuse location on a 1984--1460--000x card. Figure 5.2.20 shows the fuse location on a 1984--1304--000x card. Table 5.2.12 gives fuse data. Table 5.2.12. Contact Field Interface Card Fuses Card Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Schurter Part No. Characteristics 1984--1460--000x F1 G50382--001 4 -- -- 273.500 MSF 034.4216 1/2 A 125V Plug-In 1984--1304--000x F1 G9140--0016 AGC 1/2 312.500 -- -- 1/2 A 250V Quick Acting RS3: Serial and Analog I/O Contact Card Cage SV: 5-2-28 Contact Card Cage and Contact FlexTerm Extender Card An extender card (1984--1364--000x) is available that allows you to move contact FICs out of the card cage for easier access. The extender is marked “COORDINATOR PROCESSOR EXTENDER” on the PWA. RS3: Serial and Analog I/O Contact Card Cage SV: 5-3-1 Section 3: Multiplexer FlexTerm Hardware This section describes the Multiplexer (MUX) FlexTerm and field interface equipment, including the following components: D Multiplexer FlexTerm D MUX Power Regulator D MUX Communication D MUX Marshaling Panels D RS3: Serial and Analog I/O — Voltage MUX Marshaling Panel — Current MUX Marshaling Panel — RTD MUX Marshaling Panel Front End Modules (FEMs) — Voltage FEM — Current FEM — Resistance Temperature Detector (RTD) FEM Multiplexer FlexTerm Hardware SV: 5-3-2 MUX FlexTerm The MUX (Multiplexer) FlexTerm (1984--0620--0001) consists of a DC Power Supply, a Communication card, and Front End Modules (FEMs). Up to five FEMs can be installed for a total of 100 input points. Signals from the FEMs are fed to the Communication card, which takes 7 seconds to scan all 100 points. The individual readings are sent to the Controller Processor in the ControlFile through an isolated RS-422 communications line. Marshaling panels can be connected to the Multiplexer FlexTerm to facilitate field terminations. Figure 5.3.1 shows the Multiplexer FlexTerm. The type of FEM that is installed controls the type of Field Input that can be used. The Multiplexer FlexTerm can support these FEMs: D Thermocouple and MilliVolt input D Current input D Resistance Temperature Detector (RTD) input D Universal input FEMs are described later in this section. FEMs Communications Card Power Supply 81 61 41 21 1 100 80 60 40 20 Cable Routing Strain Relief Leave Approximately 75 cm (30 in.) to Allow Removal of FEM Figure 5.3.1. Multiplexer FlexTerm RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-3 An MPC II or MPC5 Controller Processor may control two MUX FlexTerms by use of the “Y” cable “MUX Cable Assembly, 200 Points” (1984--3062--00xx). Points in the first MUX FlexTerm have addresses 001 to 100. Those in the second MUX FlexTerm have addresses 101 to 200. The first Flex Term connects to plug P106. The second connects to plug P107. The MPC II must be loaded with the MPC2+ image and have the MPC II image functionality jumpers set to MUX+ to allow the use of up to 200 points. The MPC II baud rate jumpers (HD21--HD24) must be set to the industrial standard speed, 9600 baud. Figure 5.3.2 shows this configuration. The MPC5 must be loaded with the MPC5+ image and have the MPC5 Image Functionality jumpers set to MUX+ to allow the use of up to 200 points. ControlFile Figure 5.3.2. Two MUX FlexTerms Connected to a Controller Card RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-4 MUX Power Regulator The Multiplexer Power Regulator (1984--0605--0001) takes the system 30 volt DC bus inputs through the input switch provided on the front panel. The A and B DC buses are diode isolated. The input voltage is chopped into a square wave and sent through a transformer to produce an unregulated 300 volt square wave. This is then fed to the input of a second transformer and rectified, filtered and regulated to +5, +12, and --12 VDC. There is also a low voltage 15 KHz square wave generated for power and timing to the FEMs. Voltages are sensed for proper tolerance and this circuit drives the red/green LED pair. Figure 5.3.3 shows a functional diagram for the Multiplexer Power Regulator. Power Switch > 30 VDC A & B Power Input > 30 VDC Return > Power Regulator Outputs: +5 VDC +12 VDC --12 VDC LED Status, Control Power is sent to the processor card +5 VDC Green LED: Power Good +12 VDC Red LED: Power Bad --12 VDC MUX FlexTerm Comm Card Precision Oscillator Signal Converts crystal input to 15 kHz square wave for use by the A/D sections for timing and by the FEMs for 5V power 15 kHz Square Wave To all FEMs Figure 5.3.3. Multiplexer Power Regulator Functional Diagram RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-5 MUX Power Regulator LEDs The Multiplexer Power Regulator has red and green LEDs on the faceplate to indicate status. It also has an on-off switch. CAUTION The MUX power supply must be turned off when you install or remove boards in the MUX. MUX Communication Card The MUX Communication card (1984--0628--000x) has a 68000 microprocessor that handles all functions within the MUX FlexTerm. This includes communication with the FEMs, A/D conversion timing, thermocouple and RTD conversion, and communication to the Controller Processor card. There is also a watchdog timer that must be reset by the microprocessor or the timer will reset the microprocessor. Figure 5.3.4 shows a functional diagram for the Multiplexer Communication card. FlexTerm FEMs 5 Max in the Card Cage Multiplexer Controller RS-422 Comm MicroProcessor Command and Data Signals +5 VDC +12 VDC --12 VDC Table ROM Multiplexer Power Supply Digital A/D Section Crystal OSC 15 KHz Square Wave Figure 5.3.4. MUX Communication Card Functional Diagram RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-6 The Communication card operates by using on board RAM and single ROM for operating instructions. The Communication card also handles communication and timing for the FEM. Communication to each FEM is handled by a serial bitstream of data to sequence the input points, communicate the type of FEM, and handle the A/D timing. The Communication card and FEM (this includes all types of FEMs) comprise a dual slope analog to digital (A/D) to convert the analog voltage to a digital value that is then changed to the proper scaling by the microprocessor. The analog portion of the A/D is contained on the FEM and the digital portion of the A/D is on the Communication card. The Communication card addresses the FEM and input point on that FEM and a voltage pulse is sent to the field input for the “break detect”. This voltage pulse is normally shorted out through the field device and no residual voltage is left. If the sensor (thermocouple or RTD) is open, the voltage charge will remain on the input and the A/D will measure an overvoltage condition. A MUX Overvoltage alarm is generated for that point. The dual slope A/D converter works as follows. The Communication card sends a start instruction to the FEM. The FEM applies the unknown field voltage to a precision capacitor for a period of time determined by the timer on the Communication card, thus charging the capacitor to some voltage. The FEM then applies a precise reference voltage (negative voltage) to the same capacitor, thereby discharging it. A signal is sent from the FEM to the Communication card to indicate when the zero voltage point is reached. The Communication card uses a digital timer to measure the time between when the reference voltage is applied to the capacitor and the zero cross is detected. The digital count then represents the analog voltage. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-7 MUX Marshaling Panels There are three MUX Marshaling Panels available to connect field wiring to the MUX FlexTerm: D Voltage MUX Marshaling Panel D Current MUX Marshaling Panel D RTD MUX Marshaling Panel Voltage MUX Marshaling Panel The Voltage MUX Marshaling Panel (1984--2457--000x) is marked “ANALOG MARSHALING PANEL” on the Printed Wiring Assembly (PWA) and “VOLTAGE MUX MARSHALLING PANEL” on the label at the top. It accepts field inputs for voltage input Front End Modules. Each Voltage MUX Marshaling Panel has a total of 20 I/O points. Table 5.3.1 lists the Voltage MUX Marshaling Panel specifications. Table 5.3.1. Voltage MUX Marshaling Panel Specifications Item Specification Voltage CSA: 150V rms With a locally coated connector: 250V rms Wire gauge 4 to 0.5 mm2 (12--20 AWG) solid, stranded, or lugged Temperature Maximum: 105° C Connection to FlexTerm 50 conductor cable terminated to connector on FlexTerm motherboard Cable 1984--0500--xxxx connects the marshaling panel and the FlexTerm. The system typically ships with the cable connected. If the wires are to be connected in the field, follow Table 5.3.2. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-8 Table 5.3.2. Wiring Voltage or Current MUX Marshaling Panel to FEM Wire Color Band Color Connect to Wire Color Band Color Connect to yellow orange 1+ blue yellow 11+ orange yellow 1-- yellow blue 11-- green yellow 2+ grey black 12+ yellow green 2-- black grey 12-- brown yellow 3+ brown black 13+ yellow brown 3-- black brown 13-- yellow grey 4+ green black 14+ grey yellow 4-- black green 14-- blue white 5+ orange black 15+ white blue 5-- black orange 15-- white orange 6+ blue black 16+ orange white 6-- black blue 16-- white green 7+ grey red 17+ green white 7-- red gray 17-- white brown 8+ brown red 18+ brown white 8-- red brown 18-- white grey 9+ green red 19+ grey white 9-- red green 19-- red blue 10+ orange red 20+ blue red 10-- red orange 20-- RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-9 Current MUX Marshaling Panel The Current MUX Marshaling Panel (1984--2458--000x) is marked “MUX MARSH PANEL” on the PWA and “4--20 MUX MARSHALLING PANEL” on the label. It is designed to terminate 4--20 mA signals for MUX inputs. The 4--20 MUX Marshaling Panel accepts field inputs for three types of Front End Modules: a 4--20 mA FEM with a self-powered transmitter, a 4--20 mA FEM with system bus power, and a 4--20 mA FEM with remote power at the Marshaling panel. The 4--20 mA Marshaling Panel has 20 inputs per panel and 60 terminals for field termination. Table 5.3.3 lists the 4--20 mA MUX Marshaling Panel specifications. Table 5.3.3. 4--20 mA MUX Marshaling Panel Specifications Item Specification DC power isolation and fusing 1984--1321 fuse module with isolating diodes Per point fusing 1/4 A Temperature range 0--70° C Maximum voltage Transmitter powered: 250 V RMS System and remote powered: 150 V RMS Wire gauges 4 to 0.5 mm2 (12--20 AWG) AWG solid, stranded, or lugged Connection to FEM 50 conductor cable terminated directly to FEM terminals Cable 1984--0500--xxxx connects the marshaling panel and the FlexTerm. The system typically ships with the cable connected. If the wires are to be connected in the field, follow Table 5.3.2. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-10 RTD MUX Marshaling Panel The RTD MUX Marshaling Panel (1984--2456--000x) is marked “MULTISTRATEGY MARSHALLING PANEL” on the PWA and “RTD MUX MARSHALLING PANEL” on the label (1984--2466--000x). It accepts field inputs for RTD Front End Modules. Each RTD MUX Marshaling Panel has a total of 10 I/O points. Table 5.3.4 lists the RTD MUX Marshaling Panel specifications. Table 5.3.4. RTD MUX Marshaling Panel Specifications Item Specification Voltage CSA: 150 V RMS With a locally coated connector: 250V RMS Wire gauge 4 to 0.5 mm2 (12--20 AWG) AWG solid, stranded, or lugged Temperature Maximum: 105° C Connection to FlexTerm 50 conductor cable terminated to connector on FlexTerm motherboard. Cable 1984--0500--xxxx connects the marshaling panel and the FlexTerm. The system typically ships with the cable connected. If the wires are to be connected in the field, follow Table 5.3.5. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-11 Table 5.3.5. Wiring RTD MUX Marshaling Panel to FEM Wire Color Band Color Connect to Wire Color Band Color Connect to yellow orange 1V+ blue yellow 6V+ orange yellow 1I+ yellow blue 6I+ green yellow 1 V -- grey black 6 V -- yellow green 1 I -- black grey 6 I -- brown yellow 2V+ brown black 7V+ yellow brown 2I+ black brown 7I+ yellow grey 2 V -- green black 7 V -- grey yellow 2 I -- black green 7 I -- blue white 3V+ orange black 8V+ white blue 3I+ black orange 8I+ white orange 3 V -- blue black 8 V -- orange white 3 I -- black blue 8 I -- white green 4V+ grey red 9V+ green white 4I+ red gray 9I+ white brown 4 V -- brown red 9 V -- brown white 4 I -- red brown 9 I -- white grey 5V+ green red 10 V + grey white 5I+ red green 10 I + red blue 5 V -- orange red 10 V -- blue red 5 I -- red orange 10 I -- RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-12 When an RTD Marshaling Panel is used, four wires are run from the RTD Marshaling Panel to the FEM. Each additional wire adds to the accuracy of the temperature reading. Inaccurate readings will result when two and three wire RTDs are connected to the Marshaling Panel unless special wiring practices are followed. The inaccuracies are introduced by the added resistance of the unused wires between the Marshaling Panel and the FEM. Wiring procedures for connecting two, three, and four-wire RTDs are shown below. - To connect a two-wire RTD: 1. Connect the wires from the RTD to the V+ and V-- terminals on the Marshaling Panel as shown in Figure 5.3.5. 2. Connect the cable from the Marshaling Panel to the V+ and V-terminals of the FEM. 3. Jumper I+ to V+and I-- to V-- on the FEM. RTD V+ V+ I+ I+ V -- V -- I -- I -FEM RTD Marshaling Panel Figure 5.3.5. Connecting a Two-Wire RTD RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-13 - To connect a three-wire RTD: 1. Connect the wires from the RTD to the V+, V--, and I-- terminals on the Marshaling Panel as shown in Figure 5.3.6. 2. Connect the cable from the Marshaling Panel to the V+, V--, and I-- terminals of the FEM. 3. Jumper I+ to V+ on the FEM. RTD V+ V+ I+ I+ V -- V -- I -- I -FEM RTD Marshaling Panel Figure 5.3.6. Connecting a Three-Wire RTD - To connect a four-wire RTD: 1. Connect the wires from the RTD to the V+, V--, I+, and I-terminals on the Marshaling Panel as shown in Figure 5.3.7. 2. Connect the cable from the Marshaling Panel to the V+, V--, I+, and I-- terminals of the FEM. RTD V+ V+ I+ I+ V -- V -- I -- I -FEM RTD Marshaling Panel Figure 5.3.7. Connecting a Four-Wire RTD RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-14 MUX Front End Modules (FEMs) The MUX Front End Module (FEM) (1984--0607--000x) provides the interface between field wiring and the MUX FlexTerm. The most commonly used FEMs are: D Thermocouple and Voltage Input D Current Input D RTD Input Other specialized FEMs are available. Power for the Front End Module is provided by a low voltage 15 KHz square wave provided by the Multiplexer Power Supply. This signal is rectified, filtered, and regulated to the required voltages to operate the FEM. This same 15 KHz square wave is also used for timing the A/D sequence. All FEMs include some form of multiplexing to switch one of the 20 field inputs directly into the A/D input for evaluation every 70 milliseconds. The multiplexer circuit can utilize either solid state or reed relays. The solid state circuit has a very long life but the common mode voltage (voltage measured between any two input points on the FEM) must be below 6 VDC or damage may occur to the unit. The reed relay FEM has common mode voltage protection of 200 VDC between points. CAUTION MUX power must be OFF when FEMs are removed or inserted. The securing bar must be firmly in place to ensure that all FEM contacts are engaged. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-15 - To install a FEM in the MUX FlexTerm: 1. Ensure that the securing bar is firmly in place with a washer under the head of the screw to the FlexTerm and a washer between the securing bar and the FEM as shown in Figure 5.3.8. Securing Bar FEM Washers Mounting Screws FlexTerm Base Figure 5.3.8. Securing a FEM in the MUX RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-16 Thermocouple and Voltage FEM and Universal Voltage FEM The RTD FEM (1984--0607--0003 and 1984--0607--0009) is intended to measure the resistance of a Resistance Temperature Detector (RTD). The --0003 uses completmentary metal-oxide semiconductor (CMOS) solid state circuitry. The --0009 uses reed relays. Several ranges are available. The FEM can handle grounded or ungrounded RTDs. All inputs are multiplexed into the input of the A/D along with an internal precise 100 ohm resistor. Every cycle, this resistor value is read and the calibration is corrected to provide accurate readings. No manual calibration is required for RTD FEMs. Figure 5.3.9 shows the functional diagram for the RTD Input FEM. Multiplexer Flexterm Processor 15 kHz Power Supply 5 VDC Field Termination 20 Points Per FEM +I +V Control Section Analog A/D Section Multiplexer Switching Reed Relays or Solid State for 20 Inputs Self Calibration 100 Ohm Resistor --V --I +I 0.5 mA +V RTD Sensor + -- --V 0.5 mA Current --I Figure 5.3.9. RTD Input FEM Functional Diagram To measure the RTD through a four wire configuration, a precise 0.5 milliamp current is generated by the RTD FEM, sent to the RTD, and returned to the FEM through one pair of wires. These are the +I and --I wires. The other pair of wires is also connected across the RTD and connected to the input of the A/D converter. These are the +V and --V wires. This gives a precise reading of the voltage drop across the RTD without including the voltage drop across the current wires. RDTs are available with two, three, or four wires. The more wires used, the more accurately the resistance of the RTD may be measured. RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-17 NOTE: If an RTD Marshaling Panel is used between the RTD and the FEM, special wiring techniques are required for the use of two or three wire RTDs. See the material on the RTD Marshaling Panel earlier in this section for wiring procedures. Figure 5.3.10 shows typical wiring of four-wire and three-wire RTDs. Use of a three-wire RTD requires connecting the +I and +V wires together at the FEM. The FEM accurately measures the RTD by subtracting twice the voltage drop on the --I and --V wires from the measured voltage on the RTD. 1 2 3 I -- V -- I + V + I -- V -- I + 7 8 I -- 1 V + I -- V -- I + V -- I + 6 V + V + Jumper 6 Terminal Position 1 Three wire termination Four wire termination Orange terminal strips must be pulled out to gain access to screws. Terminal Position 6 Gray terminal strips cannot be removed. Figure 5.3.10. Field Termination of Four-Wire and Three-Wire RTDs RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-3-18 Figure 5.3.11 shows a method of terminating a two-wire RTD at the FEM. 4 -- 3 + -- + 2 -- 1 -- + + 2 Orange terminal strips must be pulled out to gain access to screws. Gray terminal strips cannot be removed. 1 Figure 5.3.11. Field Termination of a Two-Wire RTD RS3: Serial and Analog I/O Multiplexer FlexTerm Hardware SV: 5-4-1 Section 4: PLC (Programmable Logic Controller) Hardware This section covers the PLC equipment: D PLC FlexTerm D RS-422/RS-232 Port I/O card D RS-422/RS-422 Port I/O card See the I/O Block Configuration Manual (IO) for more information on using and configuring PLCs. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-2 PLC FlexTerm The PLC (Programmable Logic Controller) FlexTerm is also called the Communications FlexTerm and the RBLC FlexTerm, depending on its application. These versions are available: D 10P53200001 CE compliant version with communication line capability. D 1984--2409--0001 Original version. Table 5.4.1. Parts Replacement Part No. Replaces 10P53200001 1984--2409--0001 1984--2409--0001 10P53200001 RS3: Serial and Analog I/O Characteristics Replaces in all cases. Except in CE compliant installations or ones using the communication lines. PLC (Programmable Logic Controller) Hardware SV: 5-4-3 Figure 5.4.1 shows the 10P53200001 Flexterm and identifies the parts. Note that the motherboard part number (10P53140001) is not the same as the assembly part number. 10P53200001 1 J364 2 3 J365 1 J370 2 3 4 5 CONTROLLER 1 Y Y R G J371 4 6 7 8 Y CONTROLLER 2 Y R G Y Y R G J367 NORMAL J706 J707 J708 COMM LINE 1 COMM LINE 2 COMM LINE 3 COMM LINE 4 CONTROLLER 1 J709 J710 J711 J712 COMM LINE 1 COMM LINE 2 COMM LINE 3 COMM LINE 4 CONTROLLER 2 FISHER--ROSEMOUNT SYSTEMS, INC. PLC/RBL COM MOTHERBOARD PWA 10P53140001 HD1A HD2A HD1B HD2B REDUNDANT J939 J705 5 30VDC Power 6 7 8 9 10 11 12 13 14 15 16 Figure 5.4.1. PLC FlexTerm 10P5320000x No. Description No. Description 1 J364 Control Cable to primary Controller Processor 1 for Slots 1 and 2 9 J370 Control Cable to primary Controller Processor 2 for Slots 5 and 6 2 J365 Control Cable to optional redundant Controller Processor 1 for Slots 1 and 2 10 J371 Control Cable to optional redundant Controller Processor 2 for Slots 5 and 6 3 Slot number (Only 1, 2 and 5, 6 are used) 11 J366 Slot 1 served by Controller 1 (FIC shown installed) 4 J705--J706 Communication lines 1 and 2 for Controller 1, Port A I/O Card 12 J367 Slot 2 served by Controller 1 (No FIC shown installed) 5 J707--J708 Communication lines 3 and 4 for Controller 1, Port B I/O Card 13 J372 Slot 5 served by Controller 2 (FIC shown installed) 6 J939 DC power plug 14 J373 Slot 6 served by Controller 2 (FIC shown installed) 7 HD1A--HD1B Redundancy jumpers for Controller 1 15 J709--J710 Communication lines 1 and 2 for Controller 2, Port A I/O Card 8 HD2A--HD2B Redundancy jumpers for Controller 2 16 J711--J712 Communication lines 3 and 4 for Controller 2, Port B I/O Card RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-4 Figure 5.4.2 shows a 1984--2409--0001 PLC FlexTerm. Note that the motherboard part number (1984--2405--0001) is not the same as the assembly part number. 1984--2409--000x 1 J364 2 3 J365 1 J370 2 3 4 5 Y Y R G Y Y R G J371 6 7 8 Y Y R G NORMAL FISHER-ROSEMOUNT SYSTEMS, INC. PLC/RBL COM MOTHERBOARD PWA 1984--2405--0001 HD1A HD2A HD1B HD2B REDUNDANT J939 30VDC Power 4 5 6 7 8 9 10 11 12 Figure 5.4.2. PLC FlexTerm 1984--2409--000x No. Description No. Description 1 J364 Control Cable to primary Controller Processor 1 for Slots 1 and 2 7 J370 Control Cable to primary Controller Processor 2 for Slots 5 and 6 2 J365 Control Cable to optional redundant Controller Processor 1 for Slots 1 and 2 8 J371 Control Cable to optional redundant Controller Processor 2 for Slots 5 and 6 3 Slot number (Only 1, 2 and 5, 6 are used) 9 J366 Slot 1 served by Controller 1 (FIC shown installed) 4 J939 DC power plug 10 J367 Slot 2 served by Controller 1 (No FIC shown installed) 5 HD1A--HD1B Redundancy jumpers for Controller 1 11 J372 Slot 5 served by Controller 2 (FIC shown installed) 6 HD2A--HD2B Redundancy jumpers for Controller 2 12 J373 Slot 6 served by Controller 2 (FIC shown installed) RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-5 Either PLC Flexterm can be cabled directly from the ControlFile to the Controller 1 or Controller 2 connectors on the Flexterm as shown on the left in Figure 5.4.3. The 10P5320 Flexterm can be connected via a Remote Communications Termination Panel and two communication lines as shown at the right in Figure 5.4.3. 1 5 6 2 7 3 8 PLC 4 9 10 PLC Figure 5.4.3. PLC Flexterm Cabling No. Description No. Description 1 ControlFile with MPC Card jumpered as PLC 5 ControlFile with MPC Card jumpered as PLC 2 Control Cable 1984--2783--xxxx from ControlFile to PLC/RBL FlexTerm 6 Control Cable 1984--2783--xxxx from ControlFile to Remote Communications Termination Panel II 3 PLC/RBL FlexTerm (shown with one Port I/O Card in Slot 1) with Jumpers HD1A and HD1B set to NORMAL 7 Remote Communications Termination Panel II with redundancy jumpers HD2A and HD2B set to NORMAL 8 Communications lines 1 and 2 from TB1 and TB2 of Remote Communications Termination Panel to J705 and J706 of PLC/RBL FlexTerm 9 PLC/RBL FlexTerm (shown with one Port I/O Card in Slot 1) Jumpers HD1A and HD1B are set to NORMAL 10 Cable from Port I/O Card in Slot 1 to PLC 4 Cable from Port I/O Card in Slot 1 to PLC RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-6 Figure 5.4.4 shows wiring of a PLC FlexTerm and ControlFile to connect four PLC systems. Port I/O Card Controller Processor Card 1 RS-422 RS-422 Controller Processor Card 2 Port A PLC System 1 Port B PLC System 2 Port A PLC System 3 Port B PLC System 4 PLC FlexTerm RS-232 or RS-422 ControlFile Figure 5.4.4. PLC Cabling for Four PLC Systems The Controller Processor can be a PLC Processor card (1984--1494--000x) or a MultiPurpose Controller card (1984--2500--000x) jumpered as a PLC Processor and with the communications rate set at 9600 baud. Communication between the Controller Processor card and the PLC FlexTerm is carried by an RS-422 cable. Communication between the FlexTerm and the PLCs is carried by either an RS-232C cable or an RS-422 cable, depending on the type of Port I/O card being used. Each Controller Processor card may control two ports (A and B). Each port consists of a Port I/O card that provides connection of the PLCs to the system. The Port chosen establishes the hardware address of the Port I/O card. Port selection is by jumper on the Port I/O card. There is no correspondence between the FlexTerm slot number and the port assignment. Port A can be in slot 1 and port B in slot 2, or vice versa. For example, =F1 is the Port A Card whether it is in Slot 1 or Slot 2. Two Port I/O cards are available: RS-422/RS-232 (1984--2402--0001) and RS-422/RS-422 (1984--2441--0001). Both of these cards can be connected to any of the Controller Processor cards (A--H) by an RS-422 connection. The attributes of each port, such as the baud rate and the communication format, are configured separately on a PLC CONFIGURATION screen. There are two basic screens associated with PLCs, the PLC Configuration screen and the PLC I/O Block. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-7 Figure 5.4.5 shows an Allen-Bradley configuration. For Allen-Bradley configurations, the Port I/O card is not connected directly to the PLC, but to a module that provides an interface to a “Data HighwayÔ” (KE or KF module). The Allen-Bradley PLCs are also connected to the “Data HighwayÔ” by way of another module. A standard RS-232 cable will work to connect the Communications FlexTerm to the Allen-Bradley RS-232/Data Highway Interface. The Allen-Bradley manual has the required wiring diagrams. A Port I/O card can address one file (word) on all connected PLCs. A second card is required if another file (word) is to be addressed, as shown by the two interfaces in Figure 5.4.5. RS3 Communications FlexTerm Allen-Bradley RS-232/Data Highway Interface “B” Allen-Bradley RS-232/Data Highway Interface “A” Allen-Bradley Data Highway PLC PLC Allen-Bradley PLC Interface Module Allen-Bradley PLC Figure 5.4.5. Allen-Bradley Configuration RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-8 PLC FlexTerm Jumpers There are four jumpers on the PLC FlexTerm. The A and B jumpers must be set to the same value. Table 5.4.2 shows jumper values. NOTE: The Controller redundancy jumpers on the PLC FlexTerm motherboard have no effect if the communication line interface is used. Table 5.4.2. PLC FlexTerm Jumpers RS3: Serial and Analog I/O Jumper No Redundancy Redundancy HD1A HD1B 1--2 2--3 HD2A HD2B 1--2 2--3 PLC (Programmable Logic Controller) Hardware SV: 5-4-9 PLC Redundancy PLC redundancy may be achieved at several levels: D Redundant Controller Processor cards D Redundant Port I/O cards The basic requirements for PLC redundancy are: D The primary and redundant Port I/O cards must have the same “Device Type” field entries on their respective PLC Configuration screens. NOTE: Press [EXCHANGE] from the PLC Configuration screen to access the Port I/O (FIC) configuration fields. D D Redundant Port I/O cards must have their PLC Blocks configured as Port A. The redundant Port I/O cards must be jumpered as Port A and Port B. The Port B card backs up the Port A card. Control switches between the Port A (primary) and Port B (backup) card only when the Port A (primary) card has a fault or alarm condition. Control cannot switch back. The operator must perform an FIC reset from the PLC Configuration screen to restore the Port A card as the primary. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-10 PLC Controller Processor Redundancy Redundant Controller Processors may be used with either or both sets of Port I/O cards. Figure 5.4.6 shows cable connections to the PLC FlexTerm. If you use the Control Cable connection, the PLC FlexTerm jumpers must be set to allow redundant Controller Processors. The primary Controller Processor for FIC Slots 1--2 goes to J364. D The redundant Controller Processor for FIC Slots 1--2 goes to J365. D The primary Controller Processor for FIC Slots 5--6 goes to J370. D The redundant Controller Processor for FIC Slots 5--6 goes to J371. D If you use the communication line connection, the redundancy jumpers must be set on the Communications Termination Panel. The jumpers on the PLC/RBL panel are not used. The primary Controller Processor for FIC Slots 1--2 uses comm lines 1 and 2 to J705 and J706. D The redundant Controller Processor for FIC Slots 1--2 uses comm lines 3 and 4 to J707 and J708. D The primary Controller Processor for FIC Slots 5--6 uses comm lines 1 and 2 to J709 and J710. D The redundant Controller Processor for FIC Slots 5--6 uses comm lines 3 and 4 to J711 and J712. D J364 J365 J370 J371 J705 J706 J707 J708 COMM LINE 1 COMM LINE 2 COMM LINE 3 COMM LINE 4 CONTROLLER 1 J709 1 1 1 1 2 2 2 2 3 3 3 3 HD1A HD2A HD2B HD1B J710 J711 J712 COMM LINE 1 COMM LINE 2 COMM LINE 3 COMM LINE 4 CONTROLLER 2 Figure 5.4.6. PLC Controller Processor Redundancy Connections RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-11 PLC Port I/O Card Redundancy When redundant Port I/O cards are used, one must be jumpered as Port A and the other as Port B. The Port B card serves as backup. Figure 5.4.7 and Figure 5.4.8 show typical cabling for connecting redundant Port I/O FICs to field devices. Manual action is required to restore redundancy operation after a switch from the Port A card to the Port B card. The Port A card must be primary for redundancy to work. PeerWay Tap Configuration Terminal Data Hwy PeerWay Tap MPC Card RS-232 Cable A (Jumpered as PLC) Port A I/O Card RS-232 Data Hwy Module Analog I/O Discrete I/O PLC FlexTerms ControlFile Port B I/O Card RS-232 Cable B RS-232 Data Hwy Module PLC PLC Processor Allen-Bradley PLC System Figure 5.4.7. Port I/O Redundancy with Allen-Bradley PLC System RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-12 Communications Port PeerWay Tap MPC Card (Jumpered as PLC) Port A I/O Card RS-232 Cable A PLC FlexTerms ControlFile Modicon PLC Port B I/O Card RS-232 Cable B Communications Port Figure 5.4.8. Port I/O Redundancy with Modicon PLC System RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-13 Port I/O Card The Port I/O Cards optically isolate the system from the field and provide the interface between the Controller Processor and the field device. Two types of Port I/O cards are available: D RS-422/RS-232 Provides a RS-232 interface to the PLC. D RS-422/RS-422 Provides a RS-422 interface to the PLC. RS-422/RS-232 Port I/O Card The RS-422/RS-232 Port I/O card is connected to the Controller Processor by an RS-422 cable and to the field device by an RS-232 cable. The card is marked “INTERFACE RS-422--RS-232” on the PWA. Two versions are available: D 10P54880001 CE approved. Has green ground wire. D 1984--2402--0001 Original card. No ground wire. Table 5.4.3 shows the parts replacement rules. Table 5.4.3. Parts Replacement for the RS-422/RS-232 Port I/O Card Part No. Replaces 10P54880001 1984--2402--0001 1984--2402--0001 10P54880001 Comments Always permitted. Allowed only for non-CE approved installations. NOTE: The green ground wire of the 10P54880001 card must be fastened to one of the mounting screws of the FlexTerm. Figure 5.4.9 shows a block diagram of the RS-422/RS-232 Port I/O card. Power is supplied to the Port I/O card through a 1/2 amp power fuse (F1), which supplies 30 VDC to the card’s power regulator. The power regulator generates and regulates the DC voltages. The isolated voltages are used to power all components on the PLC side of the optical isolation. The non-isolated +5 VDC is used on the processor side of the optical isolation. Optical isolation isolates the PLC data from the processor. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-14 Fuse Blown LED DS2 (Red) 30V (B) +12 VDC Isolated --12 VDC Isolated Power Regulator 30V (A) DS1 (Green) +5 VDC Isolated Isolated Return +5 VDC Board Power Fuse 1/2 A (F1) Return Pin 1 Ground Return + TXD A Comm A TXMT -+ TXD B Comm B TXMT -- HD1C A MODEM RS-422 DS3 B Optical Isolation HD1D A RS-232 B HD2A M T HD2B M TXD Pin 2 T RCVD Pin 3 TERMINAL CTS Pin 5 + RCVR A Comm A RCVR -+ RCVR B Comm B RCVR -- HD1A A B HD1B A B RS-422 Optical Isolation RS-232 DS4 RTS Pin 4 M HD3 Optical Isolation PLC Device S +12V ISO PLC Controller +12V ISO DSR Pin 6 DTB Pin 20 DCD Pin 8 GND Pin 7 Figure 5.4.9. RS-422/RS-232 Port I/O Card Block Diagram RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-15 RS-422/RS-232 Port I/O Card RS-232 Pin Assignments The pin assignments for the RS-232C connection on the RS-422/RS-232 Port I/O card are listed in Table 5.4.4. A multipoint link uses all of the pin assignments. A single point link uses pin assignments 1, 2, 3, and 7 only. Table 5.4.4. RS-232C Pin Assignments PLC Plug (15 Pin) (For Allen Bradley KE Module only) Signal Port I/O Card (25 Pin) Signal 1 SHLD 1 SHLD 2 TXD 2 TXD 3 RXD 3 RXD 4 RTS 4 RTS 5 CTS 5 CTS 6 DSR 6 SR 7 GND 7 GND 8 DCD 8 DCD 11 DTR 11 GND 13 GND 20 DTR RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-16 RS-422/RS-232 Port I/O Card LEDs The LEDs on the RS-422/RS-232 Port I/O card are shown in Figure 5.4.10. LEDs RECEIVE DATA (DS4) Indicates that data is being received from the PLC device. TX DATA (DS3) Indicates that data is being sent to the PLC device. Y Y R 30V FUSE BLOWN (DS2) G CARD GOOD (DS1) Power fuse F1 is blown. All voltages are within tolerances. RS-232C Connector for PLC Cable Figure 5.4.10. Port I/O Card RS-422/RS-232 LEDs RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-17 RS-422/RS-232 Port I/O Card Jumpers Figure 5.4.11 shows the jumper locations on the RS-422/RS-232 Port I/O card. INTERFACE RS-422--RS-232 HD2 MODEM TERM RS-232 Plug A B HD3 M HD1 S ABCD Fuse F1 P BO AR T 1984--2402--000x Figure 5.4.11. RS-422/RS-232 Port I/O CARD Fuse and Jumpers Port Select Jumpers: Data between the Port I/O card and the Controller Processor is in RS-422 format. The data must pass through four jumpers (HD1A through HD1D) that determine whether communication port A or B is being used. Communication port A is used in normal operation. The jumpers shown in the block diagram are set for port A. The four HD1 jumpers, (A, B, C, and D) must all be at the same position. The port specified by the port select jumpers must correspond to the port specified in the interface software (PLC CONFIGURATION screen or RBL script). For example, if a Square DÔ PLC is configured on the PLC CONFIGURATION screen for port A, the jumpers on the Port I/O card connected to the Square D PLC must be set for port A. PLC CONFIGURATION screens configure the software for ports A and B. The hardware and software must be in agreement for communication with the PLC to occur. Each Port is independent: Ports A and B can communicate with different kinds of PLCs. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-18 Terminal/Modem Jumpers: Data between this Port I/O card and the PLC is in RS-232 format. A set of jumpers (HD2A and HD2B) enable the Port I/O card to be designated as the modem or terminal side of the RS-232 interface. The jumpers must be set as a pair (i.e., both jumpers must be in the same position). The terminal/modem jumpers (HD2A and HD2B) enable the Port I/O card to be set so that the transmit and receive pins on the RS-232C interface match those on the field device. If the field device transmits on pin 2 and receives on pin 3, for example, the jumpers can be set so that the Port I/O card receives on pin 2 and transmits on pin 3. In most cases, the Port I/O card should be jumpered as the modem (M position) so that pin 2 (transmit data) receives data from the field device and pin 3 (receive data) sends data to the field device. The opposite is the case if the Port I/O card is jumpered as a terminal (T position). In this case pin 2 transmits data and pin 3 receives data. Multipoint/Single Point Jumpers: The multipoint/single point jumpers (HD3) specify whether the Port I/O card is connected to a multipoint or a single point field device link. A multipoint field device link has a number of field devices on the same line. A single point field device link has only one field device on a line. If the Port I/O card is talking to one PLC, jumper HD3 should be set to the S (single point) position. This pulls RTS and CTS high all of the time. If the card is talking to more than one PLC, the jumper should be set to the M (multidrop) position. In the M position, the card uses the CTS and RTS from the PLCs. For: D D D D Allen-BradleyÔ PLCs: HD3 should be in the S (single) position. ModbusÔ protocol with one PLC on the bus: HD3 should be in the M (multipoint) position. ModbusÔ protocol with more than one PLC on the bus: HD3 position depends on the requirements of the field devices. RBL (Rosemount Basic Language) applications: HD3 position depends on the requirements of the field device. Table 5.4.5 shows the jumper values. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-19 Table 5.4.5. RS-422/RS-232 Port I/O Card Jumper Positions Jumper Position Effect HD1A--D A B Use Communications Port A Use Communications Port B HD2A--B MOD TERM Port I/O Card is a Modem Port I/O Card is a Terminal HD3 S M Single Point: One PLC Multidrop: Several PLCs RS-422/RS-232 Port I/O Card Fuse Figure 5.4.11 shows the location of the fuse on the RS-422/RS-232 Port I/O card. Table 5.4.6 shows fuse data. Table 5.4.6. RS-422/RS-232 Port I/O Card Fuse Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G50382--0014 273.500 MSF 034.4216 1/2 A 125V Plug-In RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-20 RS-422/RS-422 Port I/O Card The RS-422/RS-422 Port I/O Card is connected to the Controller processor and to the field device by RS-422 cables. The card is marked “INTERFACE RS-422--RS-422” on the PWA. There are two versions: D 10P54850001 CE approved. Has green ground wire. D 1984--2441--0001 Original card. No ground wire. Table 5.4.7 shows the parts replacement rules. Table 5.4.7. Parts Replacement for the RS-422/RS-232 Port I/O Card Part No Replaces 10P54850001 1984--2441--0001 1984--2441--0001 10P54850001 Comments Always permitted. Allowed only for non-CE approved installations. NOTE: The green ground wire of the 10P54850001 card must be fastened to one of the mounting screws of the FlexTerm. Figure 5.4.12 shows a block diagram of the RS-422/RS-422 Port I/O card (1984--2441--000x ). Power is supplied to the Port I/O card through a 2 amp power fuse (F1). The fuse supplies 30 VDC to the card power regulator. The power regulator generates and regulates the DC voltages. The isolated voltages are used to power all components on the PLC side of the optical isolation. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-21 +5V Non-isolated Fuse Blown LED DS2 (Red) Power Regulator 30V (A) 30V (B) Board Power Fuse 2 A (F1) TXD A Comm A TXMT -+ TXD B Comm B TXMT -To PLC Controller + RCVR A Comm A RCVR -+ RCVR B Comm B RCVR -- HD1C A Isolated Return Return 30V Return + +5V Isolated RS-422 Transmitter RS-422 B Pin 9+ Optical Isolation HD1D A Pin 3-- B HD1A A B HD1B A RS-422 Receiver RS-422 Optical Isolation PLC Device Pin 6+ Pin 4-- B Isolated Return Pin 5 Figure 5.4.12. RS-422/RS-422 Port I/O Card RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-22 RS-422/RS-422 Port I/O Card RS-422 Pin Assignments The pin assignments for the RS-422 connection to the PLC on the RS-422/RS-422 Port I/O card are listed in Table 5.4.8. Table 5.4.8. RS-422 Pin Assignments Pin Signal 1 To Cable Shield 3 Transmit Data -- 9 Transmit Data + 4 Receive Data -- 6 Receive Data + 5 Isolated Return RS-422/RS-422 Port I/O Card LEDs The LEDs on the RS-422/RS-422 Port I/O card are shown in Figure 5.4.13. LEDs RECEIVE DATA (DS4) Indicates that data is being received from the PLC device. TX DATA (DS3) Indicates that data is being sent to the PLC device. Y Y R 30V FUSE BLOWN (DS2) G CARD GOOD (DS1) Power fuse F1 is blown. All voltages are within tolerances. RS-232C Connector for PLC Cable Figure 5.4.13. Port I/O Card RS-422/RS-422 LEDs RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-23 RS-422/RS-422 Port I/O Card Jumpers Figure 5.4.14 shows the location of the jumpers on the RS-422/RS-422 Port I/O card. INTERFACE RS-422--RS-422 HD1 Fuse F1 ABCD P BO A R T PWA 01984--2441--0001 Figure 5.4.14. RS-422/RS-422 Port I/O Card Fuse and Jumpers The port select jumpers (HD1A--D) specify whether the Port I/O card is port A or port B. All four jumpers must be in the same position. The port specified by the port select jumpers must correspond to the port specified in the interface software (PLC CONFIGURATION screen or RBL script). For example, if a PLC is configured on the PLC CONFIGURATION screen for port A, the jumpers on the Port I/O card connected to that PLC must be set for port A. PLC CONFIGURATION screens configure the software for ports A and B. The hardware and software must be in agreement for communication with the PLC to occur. Ports A and B on the same Processor can communicate with different kinds of PLCs. There is no correspondence between the Flexterm slot number and the port. Port A can be in slot 1 and port B in slot 2, or vice versa. RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-4-24 Table 5.4.9 shows jumper values. Table 5.4.9. RS-422/RS-422 Port I/O Card Jumpers Jumper Port A Port B HD1A--D A B RS-422/RS-422 Port I/O Card Fuse Figure 5.4.14 shows the fuse location on the RS-422/RS-422 Port I/O card. Table 5.4.10 shows fuse data. Table 5.4.10. RS-422/RS-422 Port I/O Card Fuses Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 G50382--0021 273002 MSF 034.4224 2 A 125V Plug-In RS3: Serial and Analog I/O PLC (Programmable Logic Controller) Hardware SV: 5-5-1 Section 5: MultiLoop and Single-Strategy FlexTerm Hardware This section covers the MultiLoop FlexTerm, the Single-Strategy FlexTerm, and the Field Interface cards (FICs) that can be installed in the FlexTerms. Figure 5.5.1 shows the FlexTerms. Devices covered are: D MultiLoop FlexTerm D Single-Strategy FlexTerm D Analog Marshaling Panels D Analog Input Field Interface cards (FIC) D Analog Output Field Interface cards (FIC) D Analog FIC Extender card D Output Bypass Unit MultiLoop FlexTerm Single-Strategy FlexTerm Figure 5.5.1. MultiLoop and Single-Strategy FlexTerms RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-2 MultiLoop FlexTerm The MultiLoop FlexTerm (1984--1176--000x) contains two card cages for the 4 X 7 inch Field Interface cards. Each FlexTerm card cage connects to one MultiLoop Controller. The lower cage is dedicated to input Field Interface cards. The upper cage can contain either output or input Field Interface cards. Above the upper cage are eight connectors used for bypassing the outputs with the Output Bypass Unit (OBU) or for the Remote Operating Panel. There is also a connector for powering the OBU. A fuse card provides fusing for only the OBU power output. Figure 5.5.2 shows the MultiLoop FlexTerm. 1 1 Recorder Termination Card 2 3 4 5 6 7 8 2 Inputs or Outputs 9 Wire Tie Bracket 10 11 12 13 14 15 16 FICs Inputs Only 16 Two Card Cages Housing I/O Interface Cards Ground Drain Bar Field Termination Card Figure 5.5.2. MultiLoop FlexTerm RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-3 Customer wiring is connected to a Field Termination card with 32 terminals. Wiring to all FlexTerms is routed vertically between the card cages and the Field Termination card. The optional Recorder Termination card is installed on the left side of the FlexTerm. Cables from the Controller Processor and the DC power bus also enter on the left side. Both Termination cards have copper drain buses for connecting field wiring shields. A ground wire connects the drain to the chassis frame. Figure 5.5.3 shows typical field wiring. 1 Recorder Terminations -- A + B 1 Field Wire Terminations -2 + A B 2 Figure 5.5.3. Typical MultiLoop FlexTerm Field Termination RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-4 Single-Strategy FlexTerm The Single-Strategy FlexTerm (1984--1300--000x) looks similar to the MultiLoop FlexTerm. Each Single-Strategy FlexTerm, however, connects to two Single-Strategy Controller Processors. The upper and lower halves of the Single-Strategy FlexTerm each contain one Contact Field Interface card for discrete outputs, four Input Field Interface cards, and two Output Field Interface cards that can be substituted for inputs. There are two bypass connectors above each cage and a power connector for the Output Bypass Unit (OBU). Field Termination and Recorder Termination cards are identical to the MultiLoop FlexTerm. Two cables connect to the ControlFile on the left side of the motherboard, one from the upper connector of each Single-Strategy Controller. The fuse card is connected only to the Output Bypass Unit power cables. Figure 5.5.4 shows the Single-Strategy FlexTerm. Field Interface cards that can be installed into the Single-Strategy FlexTerm are the standard MultiLoop cards and either of the Contact FICs. 1 1 2 3 4 5 2 6 1 2 First Card Cage Inputs 3 Controller Cable 4 5 First Card Cage Inputs or Outputs 6 1 2 3 4 5 Not Used 6 Second Card Cage Inputs Controller Cable 16 Recorder Terminations Not Used Analog FICs Ground Drain Bar Second Card Cage Inputs or Outputs Analog Field Terminations Figure 5.5.4. Single-Strategy FlexTerm RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-5 Single-Strategy FlexTerm Analog Wiring Analog field termination points are located on a terminal strip attached to the right of the card cage. The Analog FICs are the same cards that were used in the MultiLoop. The first two pairs of terminations are not used. The second four pairs of terminations are for inputs. The next two pairs are for inputs or outputs. This order is repeated for the second card cage. A ground drain bar next to the terminal strip provides the required I/O cable ground. Single-Strategy FlexTerm Contact Wiring Terminations for 12 contact I/O points are located on a separate Contact Termination Panel (1984--1356--000x). Fusing, optical isolators, and Contact Switch Panel connections are also provided. Two Single-Strategy Controller Processor cards connect to 12 contact points on this panel (six points per controller). Figure 5.5.5 shows the Contact Termination Panel and typical wiring. OPTO Isolator Terminal strip 1st card cage Fuse 3 2 1 6 5 4 9 8 7 12 11 10 1 6 7 12 Contact field wire Terminal strip 2nd card cage Contact termination panel Figure 5.5.5. Single-Strategy Contact I/O Wiring with Contact Termination Panel Six contact I/O termination points are located on each of two terminal strips mounted on the right end of the Contact Termination Panel. The numbers 11--16, shown on each of the Contact Field Interface cards, refer to a hardware address rather than a terminal number. The six I/O contact points are controlled from the first FIC card in the card cage. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-6 CAUTION Two different phases of 220 or 120 VAC must not be connected to the same Field Termination Board on a Single-Strategy FlexTerm. Single-Strategy FlexTerm Contact Fuses Figure 5.5.5 shows the locations of the fuses on the Contact Termination Panel. Table 5.5.1 gives fuse data. Table 5.5.1. Contact Termination Panel Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics F1--F12 G09140--0060 MTH 4 312004 4 A 250V Regular RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-7 Analog Input FICs Analog Input Field Interface cards are provided in non-isolated and isolated forms. With the non-isolated Analog Input FIC there is no isolation between the controller and the field transmitter because the card references system ground. With the isolated Analog Input FIC the field transmitter can be grounded independently of the system ground. D D Non-isolated Analog Input FIC — 1984--1463--000x, marked “ANALOG INPUT NON-ISOLATED” — 1984--1394--000x, marked “FIC NON-ISOLATED INPUT” Smart Transmitter FIC — D Isolated Analog Input FIC — RS3: Serial and Analog I/O 1984--2412--000x, marked “SMART XMTR FIC” 1984--1325--000x, marked “ISOLATED INPUT” MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-8 Non-Isolated Analog Input FIC The 1984--1463--000x and 1984--1394--000x Non-Isolated Analog Input Field Interface cards convert the 4--20 mA field signal to a 1--5V analog voltage for the controller A/D converter. The --1463 card, marked “ANALOG INPUT NON-ISOLATED”, supersedes the --1394 card, which is marked “FIC NON-ISOLATED INPUT” on the PWA. Both cards perform the same function and are interchangeable. The card plugs into the MultiLoop or Single-Strategy FlexTerm. There is no isolation between the controller and the field transmitter because the card references system ground. The card is used where the transmitter is electrically floating above any ground connections. External power can be used if the remote power supply can reference the system ground. Figure 5.5.6 shows the Non-Isolated Analog Input Field Interface card functional diagram. Fuse Blown LED (Red) 30V (A) Board Power Fuse 30V (B) +28V Power Regulator Return 12V Reg Power On LED (Green) Recorder Buffer 1--5V OUT TP System Powered > From Transmitter 47V Zener Self Powered Over Voltage and Current Protection 250 Ohm Precision Analog Output to Controller Card TP 1--5V > Figure 5.5.6. Non-Isolated Analog Input Field Interface Card Block Diagram When more inputs are needed, this card can be plugged into an analog output slot, which makes that slot an input. Card edge keying protects against insertion into a slot that is not intended for this card type. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-9 Voltage regulation for the power to the transmitter is accomplished by a simple regulator circuit. The 30 VDC is applied to a 555 timer generating a square wave to the input of a transformer. As input voltage varies, the output timing of the square wave varies inversely to the input voltage changes so the voltage on the secondary of the transformer remains relatively stable. The input voltage can vary from 19 to 36 volts with less than 1 volt change in the supply output. A power-on green LED indicates the presence of +12V on the card. A and B power buses are isolated on the card by diodes. A 1/4 amp fuse protects the circuit and an LED indicates a blown fuse. The 30V rail is regulated down to +12V through a simple zener/transistor circuit. Transmitters can be powered from the FIC card power supply or from external remote power supplies. For system power, the 30V bus is connected to the positive input of the transmitter through a 1/4 amp fuse and the negative return is the 4--20 mA input. For an externally powered transmitter, the card is jumpered to ground the transmitter power leg. This makes the transmitter power leg the negative return line, referencing the field devices to the system ground (non-isolated). The remote supply positive input is then connected in series with the transmitter and the plug output is fed to the 4--20 mA input. The 4--20 mA input has a 1/4 amp fuse as well as a 27V zener for voltage and current protection of the field input. There is a current limit circuit that senses the input voltage and limits the input current to 24 mA through the card. This is accomplished by a comparator that senses the voltage and turns off a Field Effect Transistor (FET) in series with the input resistor. The heart of the card is a 250 ohm precision resistor that develops 1--5V for the 4--20 mA input. This voltage is fed directly to the controller. There is also a buffered output that is used to drive a recorder. This output is 1--5V and is current limited by the 2000 ohm resistor in the buffer circuit. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-10 Non-Isolated Analog Input FIC LEDs and Test Points Figure 5.5.7 shows the descriptions of the LEDs and test points for Non-Isolated Analog Input FICs. NOTE: There are no LED indicators to show blown fuses on the transmitter input lines. LEDs 30V FUSE The 30 VDC power fuse to the card is blown. Note that this BLOWN LED does not indicate whether field transmitter power and input current fuses are operational. R +12V STATUS (DS1) G Power is present on the card and the regulator is operational. TEST POINTS BROWN Ground return. YELLOW 1 to 5V analog signal to controller. Figure 5.5.7. Non-Isolated Analog Input FIC LEDs and Test Points RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-11 Non-Isolated Analog Input FIC Jumpers A jumper selects whether transmitters are powered from the FIC power supply or from external remote power supplies. The power type jumpers must be positioned by the user. Figure 5.5.8 shows the jumper location. Table 5.5.2 shows the Field Interface card jumper positions. HD1 F1 1--2: System-powered 2--3: Self-powered Transmitter Power F2 F3 Figure 5.5.8. Non-Isolated Analog Input FIC Fuse and Jumper Location Table 5.5.2. Non-Isolated Analog Input FIC Jumper Positions Jumper Purpose Position HD1 Specifies the power arrangement for the FIC 1--2: System supplies power to transmitter output device. 2--3: Transmitter or output device supplies its own power. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-12 Non-Isolated Analog Input FIC Fuses Figure 5.5.8 shows the locations of the fuses on the Non-Isolated Analog Input Field Interface card. Table 5.5.3 gives fuse data. Table 5.5.3. Non-Isolated Analog Input FIC Fuses Card Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics 1984--1463--000x F1 F2 F3 G09140--0010 AGC 1/4 312.250 1//4 A 250V Quick Acting 1984--1394--000x F1 F2 F3 G09140--0010 AGC 1/4 312.250 1//4 A 250V Quick Acting RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-13 Smart Transmitter FIC The Smart Transmitter FIC (1984--2412--000x) is a non-isolated analog input FIC that supports communications between the Smart transmitter and a Controller Processor. The Smart Transmitter FIC allows the system to communicate to a Smart device by sending digital information on top of the 4--20 mA signal. It is marked “SMART XMTR FIC” on the PWA. NOTE: The Smart Transmitter FIC operates with standard I/O. See the Smart Transmitter Option (1984--2483--000x) for operation with serial I/O. Smart Transmitter FIC LEDs and Test Points Figure 5.5.9 shows the LEDs and Test Points of the Smart Transmitter FIC. The “Controller” test point gives access to the 4--20 mA loop current. Measuring voltage between the “Controller” and the “GND” test points measures the loop current voltage drop across a 250 ohm precision resistor in series with the loop. LEDs TP1 Y R COMMUNICATIONS ACTIVITY (DS4) R G TP2 Indicates communications activity. The signal that enables the transmit signal from the Field Interface Card to the Controller Processor card is active. FUSE F3 BLOWN (DS3) Power fuse F3 has blown. This LED does not indicate the status of the fuses in the I/O loops. CARD BAD (DS2) A card fault is detected or communications with the Controller Processor have ceased. CARD GOOD (DS1) Card has passed power-up diagnostics. TEST POINTS TP1 Controller TP2 GND Controller loop current measured across 250 ohm resistor. Return Figure 5.5.9. Smart Transmitter FIC LEDs and Test Points RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-14 Smart Transmitter FIC Jumpers Figure 5.5.10 shows the location of the Smart Transmitter FIC jumpers. Table 5.5.4 gives jumper values. TP1 F1 F2 TP2 XMTR POWER HD1 1 SYSTEM 2 3 SELF F3 Figure 5.5.10. Smart Transmitter FIC Fuse and Jumper Locations Table 5.5.4. Smart Transmitter FIC Jumper Values Jumper Smart Transmitter Powered by System Smart Transmitter Self Powered HD1 1--2 2--3 Smart Transmitter FIC Fuses Figure 5.5.10 shows the fuses on the Smart Transmitter FIC. Table 5.5.5 gives fuse data. Table 5.5.5. Smart Transmitter FIC Fuse Data Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 F2 G50382--11 273.250 MSF 034.4213 1/4 A Plug-In F3 G50382--14 273.500 MSF 034.4216 1/2 A Plug-In RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-15 Isolated Analog Input FIC The Isolated Analog Input Field Interface card (1984--1325--000x) is very similar to the non-isolated version, with the addition of optical isolation in the voltage feedback that provides the 1--5 volts to the controller. It is marked “ISOLATED INPUT” on the printed wiring assembly (PWA). Figure 5.5.11 shows a functional diagram of the Isolated Analog Input Field Interface card. The voltage drop from the resistor is fed to a circuit that changes the voltage to a pair of pulses, a start and a stop pulse. The stop pulse is wider than the start pulse for differentiation. The timing between the pulses varies with the voltage applied. These pulses are sent through an optical isolator and decoded using the leading edge only. The result is the exact voltage that was applied to the input of the circuit. This voltage is sent to the controller. With this additional isolation, the field transmitter can be grounded independently of the system ground. Fuse Blown LED (Red) 30V (A) Board Power Fuse 30V (B) Return > Isolated Power Supply System Powered 47V Zener Fuse Power On LED (Green) Recorder Buffer 1--5V OUT Self Powered TP From Transmitter Fuse > Over Voltage And Current Protection Analog to Dual Pulse Converter Dual Pulse to Analog Converter TP 250 Ohm Precision Opto Isolation Analog Output To Controller Card 1--5V Figure 5.5.11. Isolated Analog Input FIC Functional Diagram RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-16 Isolated Analog Input FIC LEDs and Test Points Figure 5.5.12 shows the LEDs and test points for the Isolated Analog Input Field Interface card. LEDs INPUT SIGNAL (DS4) Y R 30V FUSE BLOWN (DS3) G +12V NON-ISOLATED STATUS (DS2) G +12V ISO STATUS (DS1) Indicates that the field input is present. The LED glows brighter as the field input increases. With no input, the LED is off. The 30 VDC power fuse to the card is blown. Note that this LED does not indicate whether field transmitter power and input current fuses are operational. The non-isolated +12V regulator is operational. The isolated +12V regulator is operational. TEST POINTS YELLOW BROWN 1 to 5V analog signal to controller. Ground return. Figure 5.5.12. Isolated Analog Input FIC LEDs and Test Points RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-17 Isolated Analog Input FIC Jumpers The Isolated Analog Input Field Interface card has one set of power type jumpers that must be positioned by the user. Figure 5.5.13 shows the power type jumper locations. Table 5.5.6 shows the jumper positions. F1 F2 F3 HD1 Figure 5.5.13. Isolated Analog Input FIC Fuse and Jumper Location Table 5.5.6. Isolated Analog Output FIC Jumper Positions Jumper Position HD1 1--2 System supplies power to transmitter or output device. 2--3 Transmitter or output device supplies it own power. RS3: Serial and Analog I/O Purpose MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-18 Isolated Analog Input FIC Fuses Figure 5.5.13 shows the location of the fuses on the Isolated Analog Input FIC. Table 5.5.7 gives fuse data. Table 5.5.7. Isolated Analog Output FIC Fuses Fuse FRSI Part No. Bussman Part No. Littelfuse Part No. Characteristics F1 F2 G09140--0010 AGC 1/4 312.250 1/4 A 250V Quick Acting F3 G09140--0016 AGC 1/2 312.500 1/2 A 250V Quick Acting RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-19 Analog Input Field Wiring Figure 5.5.14 shows typical analog input field wiring. Jumper J1(1--2) System Power Jumper J1 1--5V Analog Signal +28V 1 2 -- B + B Two Wire Transmitter Field Wiring Terminations System Powered Input A Jumper J1(2--3) 3 250 Ohm A + A 4--20 mA Input -- B Input Field Interface Card Equivalent Circuit Four Wire (Self-powered) Self Powered Input Transmitter Power To Transmitter Figure 5.5.14. Analog Input Field Wiring RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-20 Analog Output FICs Analog Output Field interface cards are provided in non-isolated and isolated forms. With the Non-Isolated Analog Output FIC there is no isolation between the controller and the field transmitter because the card references system ground. With the Isolated Analog Output FIC the field transmitter can be grounded independently of the system ground. The Non-Isolated Analog Output FIC includes: D 1984--1273--000x D 1984--1490--000x The Isolated Analog Output FIC includes: D 1984--1334--000x D 1984--1469--000x D 1984--1525--000x RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-21 Non-Isolated Analog Output FIC The Non-Isolated Analog Output Field Interface card (1984--1273--000x, 1984--1490--000x) receives the digital output value from the controller and converts it to a 4--20 mA signal. The return line current from the field is converted from current to voltage and fed back to the controller for a tolerance verification. There is also an integral digital hold circuit that can maintain the output of the card indefinitely if the card microprocessor should fail. The --1273 card is marked “NON-ISO ANALOG OUTPUT” and the --1490 card is marked “NON-ISOLATED OUTPUT” on the PWA. Figure 5.5.15 shows the Non-Isolated Analog Output Field Interface card functional diagram. All of the Field Interface card functions center around the 6801 microprocessor. The microprocessor is set in a special mode in which the address and data pins are used as individual ports rather than a bus function. The 6801 has an on-chip ROM (2K X 8) and RAM (128 bytes). The microprocessor handles all communications of intended output current with the controller through the optically isolated RS-422 port. Two communications wires multiplexing transmit and receive are also fed to the connector for the Analog Panel Station. The panel station is used for monitoring and backup control when the controller fails. This port uses optical isolators and an isolated +5V supply to prevent system ground loops when the controller and the FlexTerm are not powered from the same source. In case the communications from the controller and panel station are lost, there is a jumper-selectable option either to hold the last known output or drop to zero. There is also a jumper to indicate forward or reverse acting, but this is needed only in conjunction with Analog Panel Stations. The intended value of the output from the controller is converted to a 400 Hz pulse width modulated signal by the microprocessor. The 400 Hz signal is monitored by a watchdog timer. If this signal stops pulsing, the circuit resets the microprocessor. In normal operation the 400 Hz signal is routed through a switch FET and integrated by a resistor/capacitor combination and then converted to a corresponding 1--5V signal. Power for the pulse to voltage converter is supplied by a 5V three terminal regulator with a 2 percent voltage/temperature tolerance. The 1--5V signal is converted to 4--20 mA. No adjustment potentiometer is used. Close tolerance parts hold the output tolerance to less than 3 percent without feedback and better than 0.5 percent or less with feedback. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-22 A second watchdog timer monitors the 400 Hz pulse, and if it stops, the backup analog hold circuit will be switched in, thereby keeping the 1--5 volt signal driving the integrator circuit at the same voltage and holding the output current indefinitely. The analog backup hold is maintained at the same voltage level by a digital to analog (D/A) converter. An oscillator output is used to clock a counter with the output fed into a resistor network. As the counter outputs progress, the output voltage from the resistor network increases a proportional amount with each bit increase. The voltage out is compared to the integrated voltage output derived from the 400 Hz signal. As the D/A output reaches the same voltage as the signal from the microprocessor, it latches the counter output at that binary value, thus holding the output voltage at the same level. Every 100 microseconds the counter is cleared and the process starts over. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-23 +30V Analog Panel Station +10V 30V (A) 30V (B) +5V Power Regulator RETURN +5V Isolated ISO Return +5 Isolated RS-422 Comm Lines To Controller Taps +5V Comm & Isolation Receive Data Transmit Data Transmit Enable ISO Return Output Bypass Control 6801 Micro Processor Raise Lower OBU Hooked Up 400 Hz Pulse Width Modulated Signal +5V Activate Backup Hold Micro Reset +10V +30V Select +10V Output to Output Bypass Unit Voltage To Current Converter Transient Protection Backup Analog Hold To Controller Analog Input HOLD FAIL OFF 0.5 TO 2.5V Feedback 125 Ohm Precision Board Fault HOLD FAIL OFF Watchdog Timer Regulator Pulse Width To Voltage Converter 1--5V Board Enable Output to Final Control Element 24 mA Current Limit Transient Protection Final Control Element From Final Control Element Figure 5.5.15. Non-Isolated Analog Output FIC Functional Diagram RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-24 Non-Isolated Analog Output FIC LEDs and Test Points Two LEDs driven by the microprocessor indicate the microprocessor status. A yellow LED indicates transmit enable. A fourth LED indicates whether any of the three power fuses (digital, analog, or panel station power) have blown. The panel station power fuse protects against shorts in the cable going from the Field Interface card to the panel station. Refer to Chapter 3 for LEDs and test points. Figure 5.5.16 shows the Non-Isolated Analog Output FIC LEDs and test points. LEDs TX ENABLE The signal that enables the transmit signal from the Field (DS4) Interface Card to the MultiLoop Processor is active. Y R 30V FUSE One of three fuses has blown: BLOWN F3 = digital section power regulator; (DS3) F4 = analog panel station power; F5 = analog section power. This LED does not indicate the status of the two fuses on the output. R G CARD FAULT (DS3) CARD GOOD (DS1) A card fault is detected, or communications with the MultiLoop processor have ceased. If a communication problem occurs, the output current is held at its last value or goes to zero. No card faults are detected and the MultiLoop Processor or an analog panel station is controlling the output current. TEST POINTS (ON CARD BUT NOT SHOWN) BROWN Ground return YELLOW Main 5V regulator Figure 5.5.16. Non-Isolated Analog Output FIC LEDs and Test Points RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-25 Non-Isolated Analog Output FIC Jumpers The Non-Isolated Analog Output Field Interface card has one set of failure option jumpers that must be positioned by the user. Figure 5.5.17 and Figure 5.5.18 show the jumper locations. HD1 F2 F1 HD2 F5 F3 F4 Figure 5.5.17. 1985--1490--000x Non-Isolated Analog Output FIC Fuse and Jumper Locations F2 F1 HD1 F5 F3 F4 Figure 5.5.18. 1984--1273--000x Non-Isolated Analog Output FIC Fuse and Jumper Locations RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-26 Table 5.5.8 shows the jumper positions. Table 5.5.8. Non-Isolated Analog Output FIC Jumper Positions Purpose Jumper HD1 Position Indicates whether the FIC holds the last output value or sets the output current to zero if there is loss of communication with the Controller Processor card. HD2 (1984--1490--000x only) Select normal or reversed output HOLD: The last output value is held if there is a failure within the ControlFile, with the comm lines, or at the FIC. If the power supply should fail, the output current goes to zero. OFF: The output value is held for about 1/2 second before going to zero if there is a failure in the FIC processors. For other types of failures, the output value is held for up to four seconds before the output current goes to zero. 1--2: Normal Output 2--3: Reversed Output Non-Isolated Analog Output FIC Fuses Figure 5.5.17 and Figure 5.5.18 show the location of the Non-Isolated Analog Output Field Interface card fuses. Table 5.5.9 shows fuse data. Table 5.5.9. Non-Isolated Analog Output FIC Fuses Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 F2 G50382--0011 273.250 MSF 034.4213 1/4 A 125V Plug-In F3 F5 G50382--0014 273.500 MSF 034.4216 1/2 A 125V Plug-In F4 G50382--0021 273.002 MSF 034.4224 2 A 125V Plug-In RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-27 Isolated Analog Output FIC The Isolated Analog Output Field Interface card is very similar to the non-isolated version with the addition of two optical isolation circuits. D 1984--1525--000x, marked “ISOLATED OUTPUT FIC 0--20 MA” D 1984--1469--000x, marked “ISOLATED OUTPUT FIC” D 1984--1334--000x, marked “ANALOG OUTPUT ISOLATED” The first isolation circuit isolates the pulse from the microprocessor to the current converter, through an optical isolator. The second provides isolation for the voltage feedback, thus providing the 0.5--2.5 volts to the controller. The voltage drop from the resistor is fed to a circuit that changes the voltage to a pair of pulses (a start and a stop pulse), the stop pulse being wider than the start pulse for differentiation. The timing between the pulses varies with the voltage applied. These pulses are sent through an optical isolator and decoded using the leading edge only. The result is the exact voltage as applied to the input of the circuit. With this additional isolation, the field control device can reference chassis ground and not affect the functions of the system. The 0--20 mA Isolated Analog Output Field Interface card (1984--1525--000x) is similar to the 4--20 mA Isolated Analog Output FIC. Where the 4--20 mA FIC directly creates a 4--20 mA signal, the 0--20 mA FIC rescales the output signal to 0--20 mA using a precision resistor network and an isolated +10V reference. The return signal from the field device is also scaled to .5V -- 2.5V, isolated, and then returned to the microprocessor. Figure 5.5.19 shows a block diagram of the Isolated Analog Output Field Interface card. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-28 Analog Panel Station 30V (A) > +5V 30V (B) > Return > +5 Isolated RS-422 Comm Lines to Controller Taps +5V Isolated GND Receive Data Transmit Data Transmit Enable Comm and Isolation ISO Return Output Bypass Control Raise Lower OBU Hooked Up 400 Hz Pulse Width Modulated Signal Board Enable 6801 Micro processor Processor Watchdog Timer +5V Watchdog Timer Pulse Width To Voltage Converter Backup Analog Hold To Controller Analog Input Dual Pulse to Analog Converter HOLD FAIL OFF Micro-reset Field System +28V ISO 1--5V Transient Protection Select HOLD FAIL OFF Voltage To Current Converter +10V 0.5 TO 2.5V Feedback Board Fault Output To Output Bypass Unit Regulator Active Backup Hold +5V Comm Isolated Comm GND +28V Isolated +10V Isolated Switching Power Regulator Optical Isolation Analog to Dual Pulse Converter Output To Field Device Field Device +10V ISO (1525 Only) Transient Protection From Field Device Precision Resistor Network Current to Voltage Converter Figure 5.5.19. Isolated Analog Output FIC Functional Diagram RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-29 Isolated Analog Output FIC LEDs and Test Points Figure 5.5.20 shows the LEDs and test points on the Isolated Analog Output FIC. LEDs TX ENABLE (DS4) The signal that enables the transmit signal from the Field Interface Card to the MultiLoop Processor is active. 30V FUSE BLOWN (DS3) One of three fuses has blown: F3 = digital section power regulator; F4 = analog panel station power; F5 = analog section power. This LED does not indicate the status of the two fuses on the output. Y R R G CARD FAULT (DS3) CARD GOOD (DS1) A card fault is detected, or communications with the MultiLoop Processor have ceased. If a communication problem occurs, the output current is held at its last value or goes to zero (see Output Hold jumper). No card faults are detected and the MultiLoop Processor or an analog panel station is controlling the output current. TEST POINTS YELLOW Main 5V Regulator BROWN Ground Return Figure 5.5.20. Isolated Analog Output FIC LEDs and Test Points RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-30 Isolated Analog Output FIC Jumpers Figure 5.5.21 and Figure 5.5.22 show the location of the jumpers on the Isolated Analog Output FIC. Table 5.5.10 gives jumper values. F2 HD2 F1 HD1 F4 F3 Figure 5.5.21. 1984--1334--000x Isolated Analog Output FIC Fuse and Jumper Locations HD1 (A & B) A B F1 F2 HD2 F3 F4 Figure 5.5.22. 1984--1325--000x and --1469 Isolated Analog Input FIC Fuse and Jumper Locations RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-31 Table 5.5.10. Isolated Analog Output FIC Jumper Positions Card 1984--1525--000x 1984--1469--000x Jumper HD1A and HD1B Purpose Position Indicates whether the FIC holds the last output value or sets the output current to zero if there is loss of communication with the Controller Processor card. HOLD: The last output value is held if there is a failure within the ControlFile, with the comm lines, or at the FIC. If the power supply should fail, the output current goes to zero. OFF: The output value is held for about 1/2 second before going to zero if there is a failure in the FIC processors. For other types of failures, the output value is held for up to four seconds before the output current goes to zero. HD2 1984--1334--000x HD1 HD2 Select normal or reversed output Indicates whether the FIC holds the last output value or sets the output current to zero if there is loss of communication with the Controller Processor card. 1--2 Normal Output 2--3 Reversed Output HOLD: The last output value is held if there is a failure within the ControlFile, with the comm lines, or at the FIC. If the power supply should fail, the output current goes to zero. OFF: The output value is held for about 1/2 second before going to zero if there is a failure in the FIC processors. For other types of failures, the output value is held for up to four seconds before the output current goes to zero. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-32 Isolated Analog Output FIC Fuses Figure 5.5.21 and Figure 5.5.22 show the fuse locations on the Isolated Analog Output FIC. Table 5.5.11 gives fuse data. Table 5.5.11. Isolated Analog Output FIC Fuses Fuse FRSI Part No. Littelfuse Part No. Schurter Part No. Characteristics F1 F2 F3 F4 G50382--0014 273.500 MSF 034.4216 1/2 A 125V Plug-In RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-33 Analog FIC Extender Card An extender card (1984--1362--000x) is available that allows you to move the FICs out of the FlexTerm for easier access in servicing. It is marked “NON-ISO & ISO ANALOG OUTPUT/INPUT CARD EXTENDER”. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-34 Output Bypass Unit (OBU) The Output Bypass Unit (OBU) (1984--1129--000x) is used to supply uninterrupted current in place of an output Field Interface card when the card must be removed from the FlexTerm. The OBU will display the current source at the Field Interface card, provide a manual balance adjustment so that the transfer of current control to the OBU is bumpless, and then provide the current to the field device and allow manual adjustment of the output. As soon as the new Field Interface card is in place and the connector is plugged in, the Field Interface card output will automatically be balanced to the OBU output. The OBU can then be removed. Operating instructions are outlined on a sticker attached to the OBU. Figure 5.5.23 shows the unit. OUTPUT BYPASS UNIT OUTPUT BYPASS 25 20 15 10 5 0 BALANCE 5 10 15 20 25 READ INPUT Figure 5.5.23. Output Bypass Unit The OBU is capable of bypassing any type of output Field Interface card. The Output Bypass Unit has three cables. Power to the OBU from the FlexTerm is supplied through the first, output connections through the second, and the third is used to balance the Field Interface card to the OBU output after the new Field Interface card is in place. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-35 Figure 5.5.24 shows the functional diagram. The power regulator for the OBU consists of a 555 timer set up as a stable multivibrator that senses the input voltage and varies the output square wave pulse width to the transformer primary to compensate for voltage changes. The resulting regulation on the secondary of the transformer is 26 volts ±2V for an input of 19 to 36V. The variable 4--20 mA current is controlled by the front panel potentiometer by varying the input to a current source generator. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-36 28V Power Cable +30V Power Regulator Return 4--20 mA Variable Current Source Zero Center Meter Raise Balance Control + -+ 25 mA -- 25 mA Lower OBU Connected Relay Driver Latch Balance Control Cable Read Bal. Microprocessor Bypass Output Field Interface Card Output Current Cable + Final Control Element -- Analog Feedback Current Flow Sense Figure 5.5.24. Output Bypass Unit Functional Diagram A latch relay is used to prevent an improper current from driving a final control element if the OBU is connected while still in the bypass position. Once this circuit is energized it will not release unless the power is removed. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-37 A balance circuit is used to toggle the RAISE/LOWER lines to the Field Interface card to balance the Field Interface card to the OBU output. This happens only when the current flow circuit senses the current being sourced from the OBU in the bypass position. The OBU connected line tells the Field Interface card to ignore the signals coming from the controller and follow the RAISE/LOWER lines. These three outputs are optically isolated back to the Field Interface card. With the switch in the read position, the output current from the variable current source in the OBU is used to energize the relay latch driver. The relay then closes and the current from the Field Interface card is routed through the meter, to display the current to the final control element. In the balance position the current from the OBU is routed through the meter in an opposite direction from the Field Interface card read direction, thereby zeroing the meter when the currents are of equal value. In the bypass position, the current from the OBU is fed to the final control element and returned to the OBU through the meter. The Field Interface card current is bypassed around the final control element through the meter and returned to the Field Interface card analog feedback resistor. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware SV: 5-5-38 - To Bypass an output card: 1. Switch to the READ OUTPUT position on the Output Bypass Unit. 2. Connect a P047 lead to the connector mounted above the OUTPUT card slot, as shown in Figure 5.5.25. Connect a P926 lead to the power connector. The Output Bypass Unit meter shows the current provided by the output card. P047 P926 Output Bypass Unit P048 Figure 5.5.25. Connecting the Output Bypass Unit 3. Switch to the BALANCE position on the Output Bypass Unit. 4. Adjust the Output Bypass Unit control until the meter reads zero. 5. Switch to OUTPUT BYPASS position on the Output Bypass Unit. The output card can now be removed from the card cage. When the output card is removed, the meter on the Output Bypass Unit will show the current provided by the Output Bypass Unit. - To replace an output card: 1. Complete steps 1 through 5 of the above procedure. 2. Install the new output card into the card cage. 3. Connect the P048 lead to the connector on the leading edge of the output card. 4. When the Output Bypass Unit meter reads zero, switch the Output Bypass Unit to the READ OUTPUT position. The output card now controls the current. 5. Disconnect the output Bypass Unit. Disconnect leads P047 and P048. Disconnect lead P926 when finished with the output Bypass unit. RS3: Serial and Analog I/O MultiLoop and Single-Strategy FlexTerm Hardware RS3t Service Manual Chapter 6: Multipoint I/O Section 1: Section 2: Section 3: Multipoint I/O Installation and System Wiring . . . . . . . . . . . . . . . 6-1-1 Multipoint I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Address Jumpers . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Scanning Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O FIM Redundancy and Online Replacement . . . . . . . . . . . . . . . . . . . Multipoint I/O FIM Online Replacement ............................. Multipoint I/O FIM Redundancy .................................... Multipoint I/O Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel FIM Power Wiring ................... Multipoint I/O Termination Panel Communication Wiring ............... Multipoint I/O Termination Panel Communication Wiring: Online Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipoint I/O Termination Panel Communication Wiring: Redundancy . . 6-1-4 6-1-4 6-1-5 6-1-6 6-1-6 6-1-6 6-1-8 6-1-8 6-1-8 6-1-10 Communication Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-1 Remote Communications Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel II . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel II Installation . . . . . . . . . . . Remote Communications Termination Panel II Wiring . . . . . . . . . . . . . . . Remote Communications Termination Panel II Jumpers . . . . . . . . . . . . . Remote Communications Termination Panel I . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Communications Termination Panel I Installation . . . . . . . . . . . . Remote Communications Termination Panel I Wiring . . . . . . . . . . . . . . . . Remote Communications Termination Panel I Jumpers ............. Fiber Optic I/O Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Communications Wiring . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter Fiber Optic Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optic I/O Converter LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-2 6-2-4 6-2-6 6-2-6 6-2-8 6-2-9 6-2-9 6-2-9 6-2-10 6-2-11 6-2-14 6-2-15 6-2-15 6-2-16 Multipoint Discrete I/O (MDIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-1 Direct Discrete Termination Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Installation . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Field Wiring . . . . . . . . . . . . . . . . . . . . . 6-3-3 6-3-4 6-3-8 6-3-9 RS3: Multipoint I/O 6-1-10 6-1-11 Contents SV: ii Section 4: Direct Discrete Termination Panel II Jumpers . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel II Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . Direct Discrete Termination Panel Jumpers ....................... Direct Discrete Termination Panel Fuses ......................... Multi-FIM Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-FIM Discrete Termination Panel Label . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-FIM Discrete Termination Panel Jumpers ....................... Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Field Wiring ..................... Isolated Discrete Termination Panel Field Wiring Labels . . . . . . . . . . . . . Isolated Discrete Termination Panel Field Wiring Output Points . . . . . . . . Isolated Discrete Termination Panel Field Wiring Input Points . . . . . . . . . . Isolated Discrete Termination Panel Solid State Relays . . . . . . . . . . . . . . . . Isolated Discrete Termination Panel Jumpers ........................ Isolated Discrete Termination Panel Fuses .......................... High Density Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Field Wiring . . . . . . . . . . High Density Isolated Discrete Termination Panel Label . . . . . . . . . . . . . . . . High Density Isolated Discrete Termination Panel Jumpers ............ High Density Isolated Discrete Termination Panel Solid State Relays . . . . . . Discrete Field Interface Module (FIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM Online Replacement .................................. Discrete FIM Redundancy ......................................... Discrete FIM Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete FIM LED Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-10 6-3-13 6-3-14 6-3-16 6-3-16 6-3-21 6-3-22 6-3-23 6-3-25 6-3-26 6-3-28 6-3-31 6-3-33 6-3-36 6-3-37 6-3-38 6-3-39 6-3-40 6-3-41 6-3-43 6-3-43 6-3-44 6-3-45 6-3-46 6-3-48 6-3-48 6-3-49 6-3-50 6-3-51 Multipoint Analog I/O (MAIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-1 Multipoint Analog I/O Termination Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist for CE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shield Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Point Type Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Powered Input Point with External Ground Reference . . . . . . . . . . . . Self-Powered Input Point with Ground Reference at Termination Panel . Marshaling Panel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO16 Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-2 6-4-4 6-4-7 6-4-7 6-4-7 6-4-9 6-4-9 6-4-10 6-4-10 6-4-11 6-4-12 6-4-13 6-4-14 6-4-15 6-4-15 6-4-16 RS3: Multipoint I/O Contents SV: iii Section 5: Section 6: MAIO16 Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring -- Output Points . . . . . . . . . . . . . . . . MAIO Termination Panel Field Wiring -- Input Points . . . . . . . . . . . . . . . . . MAIO Termination Panel labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Loop Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAI32 Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module (LPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog FIM Redundancy .......................................... 16-Point Input FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-Point Output FIMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-Point Input FIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIM LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIO FIM LED Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single FIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundant FIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failed FIM Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-16 6-4-17 6-4-19 6-4-19 6-4-20 6-4-21 6-4-22 6-4-25 6-4-27 6-4-28 6-4-29 6-4-32 6-4-32 6-4-33 6-4-33 6-4-35 6-4-38 6-4-39 6-4-41 6-4-41 6-4-42 6-4-43 6-4-44 6-4-46 6-4-48 6-4-49 6-4-50 6-4-50 6-4-50 6-4-51 Multipoint I/O Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1 Standard Remote Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-2 Intrinsic Safety (IS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1 Elcon Series 1000 IS Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel for Discrete Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Discrete Cross Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Discrete IS Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel for Analog Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loop Power and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Analog Cross Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Analog IS Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elcon Panel Common Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-3 6-6-6 6-6-7 6-6-8 6-6-9 6-6-10 6-6-10 6-6-11 6-6-12 6-6-12 6-6-12 6-6-12 RS3: Multipoint I/O Contents SV: iv Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL IS Termination Panel for Discrete Applications . . . . . . . . . . . . . . . . . . . . . . . . Mapping I/O points to MTL Discrete Isolators . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Fault Detection (LFD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL Discrete Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel A Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel B Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL IS Termination Panel for Analog Applications . . . . . . . . . . . . . . . . . . . . . . . . . DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MTL Analog Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS3: Multipoint I/O 6-6-12 6-6-13 6-6-14 6-6-18 6-6-19 6-6-19 6-6-19 6-6-19 6-6-19 6-6-20 6-6-20 6-6-21 6-6-23 6-6-24 6-6-25 6-6-28 6-6-28 6-6-28 6-6-28 6-6-28 6-6-28 6-6-29 6-6-29 Contents SV: v List of Figures Figure Page 6.1.1. Multipoint I/O Using the Communication Termination Panel II . . . . . . . 6-1-2 6.1.2. Multipoint I/O Using the Analog Card Cage and Communication Connect Card III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-3 6.1.3. Multipoint I/O Termination Panel Addressing . . . . . . . . . . . . . . . . . . . . . . 6-1-4 6.1.4. Multipoint I/O Termination Panel Power Wiring: Option 1 . . . . . . . . . . . 6-1-8 6.1.5. Multipoint I/O Termination Panel Power Wiring: Option 2 . . . . . . . . . . 6-1-9 6.1.6. Multipoint I/O Termination Panel Communication Wiring: Online Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-10 6.1.7. Multipoint I/O Termination Panel Communication Wiring: Redundant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-11 6.2.1. Remote Communications Termination Panel II . . . . . . . . . . . . . . . . . . . . 6-2-4 6.2.2. Remote Communications Termination Panel II Used With Multipoint I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-5 6.2.3. Remote Communications Termination Panel II Field Wiring . . . . . . . . . 6-2-7 6.2.4. Remote Communications Termination Panel I . . . . . . . . . . . . . . . . . . . . 6-2-9 6.2.5. Fiber Optic I/O Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-11 6.2.6. Fiber Optic Link in a Communications Line . . . . . . . . . . . . . . . . . . . . . . . 6-2-12 6.2.7. Fiber Optic I/O Converter Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . 6-2-13 6.2.8. Power and Ground Wiring: Using the Power Jack . . . . . . . . . . . . . . . . 6-2-14 6.2.9. Power and Ground Wiring: Using the Power strip . . . . . . . . . . . . . . . . . 6-2-14 6.2.10. Communication Line Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-15 6.3.1. Recommended Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-4 6.3.2. Direct Discrete Termination Panel II (10P 5270 0001) . . . . . . . . . . . . . . 6-3-7 6.3.3. Direct Discrete Termination Panel II Keying . . . . . . . . . . . . . . . . . . . . . . 6-3-8 6.3.4. Direct Discrete Termination Panel II Field Terminals . . . . . . . . . . . . . . . 6-3-9 6.3.5. Direct Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-15 6.3.6. Direct Discrete Termination Panel Field Wiring Connections . . . . . . . . 6-3-17 6.3.7. Label for Direct Discrete Termination Field Wiring . . . . . . . . . . . . . . . . . 6-3-18 6.3.8. Label for the Direct Discrete Termination Panel . . . . . . . . . . . . . . . . . . . 6-3-19 6.3.9. Direct Discrete Termination Panel Field Wiring Connections . . . . . . . . 6-3-20 6.3.10. Multi-FIM Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . . . . 6-3-24 6.3.11. Field Wiring to a Multi-FIM Discrete Termination Panel . . . . . . . . . . . . . 6-3-25 6.3.12. Isolated Discrete Termination Panel A . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-29 6.3.13. Isolated Discrete Termination Panel B . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-30 RS3: Multipoint I/O Contents SV: vi 6.3.14. Isolated Discrete Termination Panel Field Wiring Connections . . . . . . 6-3-32 6.3.15. Label for Isolated Discrete Termination Field Wiring Panel A . . . . . . . . 6-3-33 6.3.16. Label for Isolated Discrete Termination Panel A . . . . . . . . . . . . . . . . . . . 6-3-34 6.3.17. Label for Isolated Discrete Termination Panel B . . . . . . . . . . . . . . . . . . . 6-3-35 6.3.18. System-Powered Output Point Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-36 6.3.19. Field-Powered Output Point Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-36 6.3.20. Contact-Closure Input Point Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-37 6.3.21. Field-Powered Input Point Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-37 6.3.22. High Density Isolated Discrete Termination Panel . . . . . . . . . . . . . . . . . 6-3-42 6.3.23. Field Wiring to a Multi-FIM Discrete Termination Panel . . . . . . . . . . . . . 6-3-43 6.3.24. Discrete Field Interface Module (FIM) Block Diagram . . . . . . . . . . . . . . 6-3-47 6.3.25. Discrete Field Interface Module (FIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-50 6.4.1. MAIO16 Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-5 6.4.2. MAIO16 Termination Panel Field Wire Landing Methods . . . . . . . . . . . 6-4-10 6.4.3. MAIO16 Output Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-11 6.4.4. MAIO16 System-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-12 6.4.5. MAIO16 Self-Powered Input Point with External Ground Reference . . 6-4-13 6.4.6. MAIO16 Self-Powered Input Point with Ground Reference at Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-14 6.4.7. MAIO Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-18 6.4.8. Field I/O Point Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-20 6.4.9. Output Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-21 6.4.10. System-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-22 6.4.11. Self-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-23 6.4.12. Self-Powered Input Point (Referred to Loop Power Return: Non-isolated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-24 6.4.13. MAIO Termination Panel Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-26 6.4.14. MAI32 Analog Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-30 6.4.15. MAI32 Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-33 6.4.16. MAI32 Field Wiring Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-34 6.4.17. System-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-36 6.4.18. Self-Powered Input Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-37 6.4.19. Loop Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-39 6.4.20. Loop Power Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-40 6.4.21. MAIO 16-Point Input FIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-44 6.4.22. MAIO 16-Point Input FIM Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-45 6.4.23. MAIO 16-Point Output FIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-46 6.4.24. MAIO 16-Point Output FIM Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 6-4-47 RS3: Multipoint I/O Contents SV: vii 6.4.25. MAIO 32-Point Input FIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-48 6.5.1. Standard Remote Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-2 6.6.1. Intrinsic Safety Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-1 6.6.2. Elcon Intrinsically Safe Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . 6-6-4 6.6.3. Discrete I/O with Elcon IS Termination Panel . . . . . . . . . . . . . . . . . . . . . 6-6-6 6.6.4. Elcon Panel Cross Wiring for Discrete Applications . . . . . . . . . . . . . . . . 6-6-7 6.6.5. Elcon Discrete Panel Polarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-8 6.6.6. Analog I/O with Elcon IS Termination Panel . . . . . . . . . . . . . . . . . . . . . . 6-6-9 6.6.7. Elcon Panel Cross Wiring for Analog Applications . . . . . . . . . . . . . . . . . 6-6-10 6.6.8. Elcon Analog Panel Polarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-11 6.6.9. MTL Discrete IS Termination Panel A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-15 6.6.10. MTL Discrete IS Termination Panel B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-16 6.6.11. Discrete I/O with MDIO MTL IS Termination Panel A and B . . . . . . . . . 6-6-17 6.6.12. LFD Jumper Settings for Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-23 6.6.13. LFD Jumper Settings for Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-23 6.6.14. MTL Analog IS Termination Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-26 6.6.15. Analog I/O with MTL IS Termination Panel . . . . . . . . . . . . . . . . . . . . . . . 6-6-27 RS3: Multipoint I/O Contents SV: viii List of Tables Table Page 6.1.1. I/O Point and Minimum Controller Scan Rates . . . . . . . . . . . . . . . . . . . . . . 6-1-5 6.2.1. Remote Communications Termination Panel Parts Replacement . . . . . . . 6-2-2 6.2.2. Remote Communications Terminal Panel II Jumpers . . . . . . . . . . . . . . . . 6-2-8 6.2.3. Remote Communications Termination Panel I Jumpers . . . . . . . . . . . . . . 6-2-10 6.2.4. Fiber Optic I/O Converter LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-16 6.3.1. Parts Replacement for the Direct Discrete Termination Panel . . . . . . . . . 6-3-3 6.3.2. Direct Discrete Termination Panel II Jumper Settings ............... 6-3-10 6.3.3. Direct Discrete Termination Panel II Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-13 6.3.4. Direct Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-21 6.3.5. Direct Discrete Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-22 6.3.6. Multi-FIM Discrete Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . 6-3-27 6.3.7. Solid State Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-38 6.3.8. Isolated Discrete Termination Panel A Jumpers . . . . . . . . . . . . . . . . . . . . . 6-3-39 6.3.9. Isolated Discrete Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-40 6.3.10. High Density Isolated Discrete Termination Panel Address Jumpers . . . 6-3-44 6.3.11. High Density Isolated Discrete Termination Panel, Solid State Relays . 6-3-45 6.3.12. Parts Replacement for the Discrete Field Interface Module . . . . . . . . . . 6-3-46 6.3.13. MDIO, MDIOH, and MDIOL LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-50 6.4.1. Multipoint Analog I/O Termination Panel Parts Replacement ......... 6-4-3 6.4.2. MAIO16 Termination Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-6 6.4.3. MAIO Marshaling Panel Cable Pin-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-15 6.4.4. MAIO16 Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-16 6.4.5. MAIO Termination Panel Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-28 6.4.6. MAI32 Analog Termination Panel Components ..................... 6-4-31 ............................... 6-4-35 6.4.8. MAI32 Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-38 6.4.9. Loop Power Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-41 6.4.10. MAIO FIM Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-42 6.4.11. MAIO FIM LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-49 6.4.12. MAIO FIM LED Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-51 6.5.1. Standard Remote Termination Panel, Marshaling Panel Cable . . . . . . . . . 6-5-3 6.6.1. Elcon IS Termination Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-5 6.4.7. MAI32 Termination Panel Jumpers RS3: Multipoint I/O Contents SV: ix 6.6.2. Elcon Discrete IS Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.3. Elcon Analog IS Barriers 6-6-8 ........................................ 6-6-11 6.6.4. Elcon IS Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-13 6.6.5. Mapping of I/O Points to MTL Discrete Panel A Isolators . . . . . . . . . . . . . 6-6-18 6.6.6. Mapping of I/O Points to MTL Discrete Panel B Isolators . . . . . . . . . . . . . 6-6-18 6.6.7. MTL Discrete IS Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-20 6.6.8. MTL Discrete IS Isolators ....................................... 6-6-22 6.6.9. MTL Analog IS Termination Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-28 6.6.10. MTL Analog Input and Output Isolators 6-6-29 RS3: Multipoint I/O .......................... Contents SV: x RS3: Multipoint I/O Contents SV: 6-1-1 Section 1: Multipoint I/O Installation and System Wiring Multipoint I/O (MIO) is a family of I/O products that allow for the distribution of the I/O electronics and marshaling panels close to the I/O devices controlled. The devices share a common packaging format and system cable connection method. Multipoint I/O is used to read and control analog and discrete (contact) I/O points. The MIO Termination Panel provides connection for field I/O devices, one or two Field Interface Modules (FIM), optional Loop Power Module (LPM), and communications to the Controller Processor in a ControlFile. Most Multipoint I/O termination panels provide the option of online Field Interface Module (FIM) replacement or redundant FIM operation. For online replacement operation, a single FIM is installed and a single communication line is used. If this FIM fails, a replacement may be inserted in the empty socket. The replacement will take over for the failed FIM. Redundant operation requires two installed FIMs, two communication lines, and use of a Redundant I/O Block (RIOB). Both FIMs operate continuously with one as primary, the other as secondary. If the primary FIM fails, the secondary FIM takes over immediately. A Communication Connect Card III, Communication Termination Panel II, or Remote Communication Termination Panel provides up to eight communications lines between an MPC controller in a ControlFile and the MIO termination panels. Up to four MIO termination panels can be connected to each communication line, with each panel having a separate address. Configuration space and processor time will limit the amount of hardware that can be connected and serviced. A pair of Fiber Optic I/O Converters can be used to insert a fiber optic link in the communication line. RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-2 Multipoint I/O termination panels can be connected directly to a ControlFile by using a Communications Termination Panel II (1984--4205--000x) or a Remote Communications Termination Panel (1984--2552--000x). Figure 6.1.1 shows a typical installation. PeerWay A A B B ControlFile Control Cable Communication Termination Panel II Controller Communication Lines Multipoint I/O Termination Panel Figure 6.1.1. Multipoint I/O Using the Communication Termination Panel II RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-3 Multipoint I/O termination panels can be connected to an Analog Card Cage using a Communications Connect Card III (1984--2543--000x). Figure 6.1.2 shows a typical installation. PeerWay A A B B ControlFile Communication Connect Card III Control Cable Controller Analog Card Cage Communication Lines Multipoint I/O Termination Panel Figure 6.1.2. Multipoint I/O Using the Analog Card Cage and Communication Connect Card III RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-4 Multipoint I/O Addressing Figure 6.1.3 shows how Multipoint I/O addresses are formed. The standard RS3 address format has been generalized to make the new hardware configuration fit logically within the familiar RS3 address structure. The ControlFile Node Address specifies which ControlFile is used. The Controller Slot Address specifies which controller is used. The “Cage Address” specifies which termination panel on the communication line is used. The communication line or “Card Cage Slot” specifies which communication line is used. The Point Address specifies which I/O point is used. =2 G A 2 11 ControlFile Node Address (1--992) Controller Slot Address (A--H) Termination Panel Address “Cage” Address (A--D) Point Address (01--32) Communication Line Address “Card Cage Slot” (1--8) Figure 6.1.3. Multipoint I/O Termination Panel Addressing Multipoint I/O Termination Panel Address Jumpers The termination panel address or “card cage address” is specified by a jumper that is set to address A, B, C, or D. The isolated Discrete Termination Panel pair has an address jumper on each of the two panels. Both must be set to the same address. The MultiFIM Discrete Termination Panel has a separate address jumper for each of the three FIMs. RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-5 Multipoint I/O Scanning Rates The rate at which I/O points are scanned depends on the highest card cage address served by the communication line. D D D D The maximum panel scanning rate of 32 per second is achieved when only address “A” is used on the communication line; the scanning pattern is “A A A A”. Using address “B” halves the rate for all points to 16 scans per second; the scanning pattern is “A B A B”. Using address “C” gives 16 scans per second to A and 8 each to B and C; the scanning pattern is “A B A C”. Using address “D”, gives 8 scans per second to all; the scanning pattern is “A B C D”. The Multipoint Discrete I/O (MDIO) I/O point update rate is equal to the panel scan rate. The Multipoint Analog I/O (MAIO) I/O point update rate is one-fourth the panel scan rate. Four messages are needed to update the points, so the analog I/O point update rate is the panel scan rate divided by 4. Thus a MAIO panel addressed as “A”, with a panel scan rate of 32 scans per second, gives 8 I/O point scans per second or a scan time of .125 second. The minimum useable controller scan time is .25 second. Table 6.1.1 shows the scan rates and minimum controller scan time for various cage addresses. NOTE: The controller scan time (1.0, .50, .25, .125 second), selected from the ControlFile Status screen, must always be greater than the I/O point scan time. The controller scan time applies to all card cages served by the controller, so the scan time of the slowest cage must be used. Table 6.1.1. I/O Point and Minimum Controller Scan Rates Highest Card Cage Address Cage Scan Rate Minimum Controller Scan Time (Seconds) Cage Scan Pattern (Scans Per Second) MDIO MAIO A AAAA 32 .125 .25 B ABAB 16 .125 .50 C ABAC .25 25 10 1.0 D ABCD .25 1.0 RS3: Multipoint I/O A: 16 B, C: 8 8 Multipoint I/O Installation and System Wiring SV: 6-1-6 Multipoint I/O FIM Redundancy and Online Replacement Most Multipoint I/O termination panels support FIM redundancy and FIM online replacement. Multipoint I/O FIM Online Replacement The online replacement operation is provided when one FIM and one communication line is used. The FIM can be installed in either the “A” or the “B” socket. The other socket is available for an online replacement. The redundancy jumper(s) must be set to normal to allow the online replacement operation. If the FIM fails in any way, a good FIM can be plugged into the empty socket. Normally, the failed FIM red LED goes ON. The new FIM takes over from the installed FIM in a few seconds. The failed FIM can be removed for repair as soon as the new FIM green LED goes ON and the yellow “Comm Active” LED (see note below) flashes. NOTE: The label for a discrete FIM is marked “Comm Active”. Current labels for analog FIMs are marked “Comm A” and “Comm B”. Older labels for analog FIMs were marked “Port A” and “Port B”. NOTE: The new FIM may be left in service in that socket; the failed FIM should be removed immediately. The empty socket will provide for another online replacement. Do not leave two FIMs plugged into an online replacement style panel. Multipoint I/O FIM Redundancy Full FIM redundancy is provided when two FIMs are used. Two communication lines are required, one for an odd numbered slot and one for the next even numbered slot. The primary FIM is in the “FIM A” socket and the redundant FIM is in the “FIM B” socket. The redundancy jumper(s) must be set at redundant to allow redundant operation. A Redundant I/O Block (RIOB) must be configured to control operations. Analog FIM redundancy requires that the jumpers at HD18 and HD19 on the Analog Termination Panel be set to the “R” position while discrete FIM redundancy requires that the jumpers at HD2 on the Discrete Termination Panel be removed. The odd numbered slot address must be wired to FIM A, the “primary” FIM. The even numbered slot must be wired to FIM B, the “secondary” FIM. RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-7 Primary (A) FIM Failure: If the primary FIM fails, the secondary FIM takes over and assumes the duties of the primary. Normally the failed FIM red LED goes ON and the green LED flashes. The failed FIM should be removed and replaced. As soon as the new FIM A powers up, it assumes the duties of the primary FIM and FIM B returns to secondary operation. Secondary (B) FIM Failure: If the secondary FIM (B) fails, the primary FIM (A) continues to operate. Normally, the failed FIM red LED goes ON and the green LED flashes. The failed FIM B should be removed and replaced. As soon as the new FIM B powers up, it resumes the duties of secondary FIM. RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-8 Multipoint I/O Termination Panel Installation The termination panel must be mounted with the long dimension placed vertically. The panel can be installed in a rack, on DIN rails, or against a flat surface. Ambient air temperature specifications refer to the temperature of the air at the bottom of each terminal panel. Wire tie-wrap anchor points are provided on the label bracket at each end of the panel. Multipoint I/O Termination Panel Grounding The termination panel must be connected to the cabinet ground. If the panel is mounted on a grounded DIN rail or mounted against a grounded metal panel it will be adequately grounded. Otherwise you must connect a ground wire to one of the ground terminals of the power strip. Multipoint I/O Termination Panel FIM Power Wiring NOTE: Removing power from a termination panel stops processing for all points served by the panel. Terminal panel (FIM) power is supplied either from the RS3 system DC power supply bus or from a local DC source such as a Remote I/O Power Supply (1984--4302--00xx). Provision is made for optional A and B redundant DC supplies. There are two approved ways to supply FIM power. Option 1 uses the standard RS3 4-pin power jack and a standard RS3 DC power cable as shown in Figure 6.1.4. Power Jack Power Strip Power Jack A Supply B Supply A Return Standard A and B Power Supply Cable B Return Figure 6.1.4. Multipoint I/O Termination Panel Power Wiring: Option 1 RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-9 Option 2 is more suitable if FIM power is supplied by a local source or if additional panels are to be fed from the same source. Figure 6.1.5 shows option 2. From A From B Supply Supply A & B Power to another unit (10 amp max A+B) A B RTN A B Power Strip RTN A+ A -- A -A+ B+ B -- B -B+ Daisy chain to next device NOTE: Maximum current (A + B) 7 amps Figure 6.1.5. Multipoint I/O Termination Panel Power Wiring: Option 2 CAUTION Do not use both the power jack and the power strip at the same time. This may result in damage to the panel. RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-10 Multipoint I/O Termination Panel Communication Wiring Port A and Port B provide for connecting two independent communication lines. The communication line used determines the panel slot address. One line is used for single FIM (online replacement) applications. An odd-even pair is used for redundant FIM applications. Each terminal is labeled +, --, and S for the plus and minus signal wires and the shield. The terminals will accommodate one wire of 0.34 to 4 mm2 (22 to 12 AWG) size or two wires in the range 0.34 to 0.75 mm2 (22 to 18 AWG). This allows communication wires to be daisy chained to other panels as required. Shield grounding is supplied within the termination panel. An internal spark gap transient suppressor is supplied on the communication lines and within the FIM. A low impedance connection between the panel and local ground is required for proper protection. No further transient suppression should be required. Multipoint I/O Termination Panel Communication Wiring: Online Replacement The communication line can be connected to Port A or Port B. The other port can be used to daisy chain the communication line to another panel. NOTE: It is good practice to use an odd numbered line and to reserve the next even numbered line for eventual redundant operation. The redundancy jumpers connect the communication lines to allow for an online replacement operation with a single line. These jumpers must be at normal for online replacement operation. Figure 6.1.6 shows communication wiring for the single FIM (online replacement) application. Communication Line Slot N (odd) Port A NOTE: Redundancy jumpers must be on normal Figure 6.1.6. Multipoint I/O Termination Panel Communication Wiring: Online Replacement RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-11 Multipoint I/O Termination Panel Communication Wiring: Redundancy The use of redundant FIMs requires two independent communication lines as shown in Figure 6.1.7. The odd numbered line must be wired to Port A, for FIM A (the “primary” FIM). The even numbered line must be wired to Port B for FIM B (the “secondary” FIM). The redundancy jumpers must be set at redundant to allow the use of the two independent communication lines. Communication Line Slot N+1 (even) Communication line slot N (odd) Port A Port B NOTE: Redundancy jumpers must be set at redundant Figure 6.1.7. Multipoint I/O Termination Panel Communication Wiring: Redundant Operation RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-1-12 RS3: Multipoint I/O Multipoint I/O Installation and System Wiring SV: 6-2-1 Section 2: Communication Devices This section covers devices that connect Multipoint I/O termination panels to the ControlFile: D Remote Communications Termination Panel D Fiber Optic I/O Converter Another device used is covered in Section 1 “Analog Card Cage”: D RS3: Multipoint I/O Communications Connect Card Communication Devices SV: 6-2-2 Remote Communications Termination Panel There are two models of the Remote Communications Termination Panel (also known as the Communications Termination Panel): D D Remote Communications Termination Panel II (1984--4205--000x) is marked “COMM TERM PNL II” on the PWA. This panel provides one set of communication lines. Remote Communications Termination Panel I (1984--2552--000x) is marked “COMM TERMINATION PNL” on the PWA. This panel provides two independent sets of communication lines. It essentially is two single panels mounted together. Table 6.2.1 shows a replacement for this unit. The Remote Communications Termination Panel provides termination and transient suppression for communication lines between a Controller Processor and a Multipoint I/O termination panel, an analog card cage, or a FlexTerm for long distance applications. When used with a ControlFile and Contact FlexTerm or with a PLC FlexTerm, a Remote Communications Termination Panel must be installed at each end of the communication link. The panel must be mounted in the same cabinet or set of cabinets as the ControlFile or remote I/O to which it is attached. When used with a Multipoint I/O termination panel, only one Remote Communications Termination Panel is required. The Multipoint I/O termination panel provides adequate termination for the other end of the communication lines. NOTE: A Remote Communications Termination Panel cannot be used with Single-Strategy or MultiLoop FlexTerms. NOTE: The Communications Connect Card also provides termination and transient suppression for communication lines. It may be used in place of a Remote Communications Termination Panel II. Table 6.2.1. Remote Communications Termination Panel Parts Replacement Part No. 1984--4409--0001 (Kit) RS3: Multipoint I/O Replaces Characteristics 1984--2552--000x The kit replaces a Remote Communications Termination Panel I. The kit has two Remote Communications Termination Panel II units and a DIN rail for mounting them. Communication Devices SV: 6-2-3 NOTE: The transient suppression networks are sufficient for cables within a building. For runs between buildings, lightning arrestors should be provided where the cable enters the building. The use of metal conduit or a copper ground wire is recommended. You can also use the Fiber Optic I/O Converter to put a fiber optic link in the communication line. RS3: Multipoint I/O Communication Devices SV: 6-2-4 Remote Communications Termination Panel II Figure 6.2.1 shows the Remote Communications Termination Panel II. There are two connectors on each panel for a pair of redundant Controller Processors or for daisy chain cabling to a local card cage or FlexTerm. The panel features a pair of transient suppression diodes for each communications line to protect the Controller Processor. NOTE: The panel is shipped with a ground wire attached to TB9. This must be connected to chassis ground for proper operation of the transient protection. The other terminal of TB9 may be used to ground the communications cable overall (external) shield. The overall shield must be grounded only at the ControlFile end of the run. 2 J567 40 HD2A HD2B 1 NORM 2 39 RED 40 J568 3 39 1 TB1 TB2 TB3 TB4 TB5 OVERALL SHIELD CONNECT AT CONTROL FILE AREA TB6 TB7 TB8 HD1 REMOTE I/O CONT FILE AREA TB9 Ground Cable to Chassis Ground Figure 6.2.1. Remote Communications Termination Panel II Figure 6.2.2 shows how the Remote Communications Termination Panel II is used with Multipoint I/O termination panels. RS3: Multipoint I/O Communication Devices SV: 6-2-5 PeerWay A A B B ControlFile Control Cable Communication Termination Panel II Controller Communications Lines Isolated Discrete I/O Termination Panel Direct Discrete I/O Termination Panel Figure 6.2.2. Remote Communications Termination Panel II Used With Multipoint I/O RS3: Multipoint I/O Communication Devices SV: 6-2-6 Remote Communications Termination Panel II Installation The Remote Communications Terminal Panel II (1984--4205--000x) is mounted on a DIN rail. It is approximately 77 x 200 mm (3 x 7.9 in.). There are plastic loops at each corner of the panel for attaching strain relief ties. NOTE: The chassis ground wire (green) must be connected to a good ground or system transient immunity will be severely compromised. Terminal TB9 may also be used for grounding a communication line overall cable shield (if any is present). Remote Communications Termination Panel II Wiring The Remote Communications Termination Panel II provides two connectors for cables to Controller Processor or to a local card cage or FlexTerm. Eight terminals (TB1--TB8) are provided for connecting individually shielded twisted--pair communication lines. The individual shields must be terminated at both ends of the cable. A 50P05890103 (G53373--0103) mating connector is used on the communication line. The communication line establishes the slot address of the device connected to the line. Figure 6.2.3 shows typical wiring for use with a Multipoint I/O termination panel. For each twisted pair, connect the shield (or drain) to “S”, the black wire to “--”, and the red wire to “+”. NOTE: If the communication lines are gathered into a shielded cable, the overall cable shield must be grounded to terminal TB9 only at the ControlFile end of the cable run. RS3: Multipoint I/O Communication Devices SV: 6-2-7 To ControlFile 2 40 J567 HD4A HD4B 1 NORMAL 2 39 REDUNDANT J568 40 3 1 COMM 1 TB1 39 COMM COMM COMM COMM COMM COMM COMM 2 3 4 5 6 7 8 TB2 TB3 TB4 TB5 TB6 TB7 TB8 OVERALL SHIELD CONNECT AT CONTROL FILE AREA HD1 REMOTE I/O CONT FILE TB9 Ground Cable to Chassis Ground Terminals for Communication Lines 1--8 (Each of these connections has +, -- , shield) Figure 6.2.3. Remote Communications Termination Panel II Field Wiring RS3: Multipoint I/O Communication Devices SV: 6-2-8 Remote Communications Termination Panel II Jumpers There are jumpers on each panel to specify the location of the panel and whether normal or redundant Controller Processor operation is being used. Table 6.2.2 shows jumper positions for the Remote Communications Terminal Panel II. Table 6.2.2. Remote Communications Terminal Panel II Jumpers Jumper Position Effect HD1 REMOTE I/O (1--2) Used when the panel is at the remote end of the communication line; at the card cage or FlexTerm. CONT FILE (2--3) Used when the panel is at the ControlFile (source) end of the communication line. HD4A HD4B NORMAL (1--2) REDUNDANT (2--3) RS3: Multipoint I/O Normal operation. One cable is used from the ControlFile to the panel. The panel is connected to one Controller Processor. Redundant operation. Two cables are used between the ControlFile and the panel. The panel is connected to two Controller Processors. Communication Devices SV: 6-2-9 Remote Communications Termination Panel I Remote Communications Termination Panel I (1984--2552--000x) handles two independent communication terminations. The upper half of the panel handles one termination, the lower half the other termination. Each provides two connectors for cables to the Controller Processor or to a local card cage or FlexTerm. Figure 6.2.4 shows the Remote Communications Termination Panel I. A kit (1984--4409--000x) is available to replace this unit. 6 8 2 3 4 5 7 1 + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S + -- S 1 2 3 4 5 6 7 8 Figure 6.2.4. Remote Communications Termination Panel I Remote Communications Termination Panel I Installation The Remote Communications Termination Panel I is mounted in a standard 19-inch rack. Remote Communications Termination Panel I Wiring Two sockets are provided for the cable from the Controller Processor and for the optional redundant Controller Processor. Eight sets of screw connections are provided for connecting individually shielded, twisted-pair communication lines. The individual shields must be terminated at both ends of the cable. The communication line establishes the slot address of the device connected to the line. NOTE: If the communication lines are gathered into a shielded cable, the overall cable shield should be grounded to the “Overall Shield” terminal only at the ControlFile end of the cable run. RS3: Multipoint I/O Communication Devices SV: 6-2-10 Remote Communications Termination Panel I Jumpers There are jumpers on each panel to specify the location of the panel and whether normal or redundant operation is being used. Table 6.2.3 shows jumper positions for the Remote Communications Termination Panel I. Table 6.2.3. Remote Communications Termination Panel I Jumpers Jumper HD1A HD1B (Top panel) HD3 (Top panel) HD2A HD2B (Lower panel) HD4 (Lower panel) RS3: Multipoint I/O Position Effect NORMAL (1--2) Normal operation. One cable is used from the ControlFile to the panel. REDUNDANT (2--3) Redundant operation. Two cables are used between the ControlFile and the panel. REMOTE I/O (1--2) Used when the panel is at the remote end of the communication line, at the card cage or FlexTerm. CONTROL FILE (2--3) NORMAL (1--2) Used when the panel is at the ControlFile (source) end of the communication line. Normal operation. One cable is used from the ControlFile to the panel. REDUNDANT (2--3) Redundant operation. Two cables are used between the ControlFile and the panel. REMOTE I/O (1--2) Used when the panel is at the remote end of the communication line, at the card cage or FlexTerm. CONTROL FILE (2--3) Used when the panel is at the ControlFile (source) end of the communication line. Communication Devices SV: 6-2-11 Fiber Optic I/O Converter The Fiber Optic I/O Converter (1984--3278--000x) allows for the insertion of one fiber optic link in a twisted pair communications line between a controller and an I/O device. Two converters are required, one at either end of the fiber optic link. NOTE: Revision Level C/D or higher includes the ground wire and DIN rail clip. Figure 6.2.5 shows front and top views of the converter. Top View FIBER OPTIC I/O CONVERTER 5V POWER CF NODE RECEIVE DATA CONTROLLER TRANSMIT DATA COMM LINE TB1 F/O Receiver R TB2 TB3 J980 A B RTN T F/O Transmitter Power Strip Power Jack Comm Ports (three position) Ground Wire and DIN Clip Front View Figure 6.2.5. Fiber Optic I/O Converter RS3: Multipoint I/O Communication Devices SV: 6-2-12 Figure 6.2.6 shows a typical installation. NOTE: Only one fiber optic link may be used in a communication line run. PeerWay A A B B ControlFile Controller to FlexTerm Cable Communication Termination Panel II Fiber Optic I/O Converter Controller Communication Line Fiber Optic Cable Fiber Optic I/O Converter Communication Line Figure 6.2.6. Fiber Optic Link in a Communications Line RS3: Multipoint I/O Communication Devices SV: 6-2-13 The operation of the Fiber Optic I/O Converter is divided into four subgroups. Figure 6.2.7 is the converter block diagram. +5V Vin +5V DC/DC Power Supply Fiber Optic Receiver Fiber Optic Input Fiber +5V + -Shield Communications Line RS-485/Digital Communications Converter +5V Fiber Optic Transmitter Fiber Optic Output Fiber Figure 6.2.7. Fiber Optic I/O Converter Block Diagram The power supply section converts 18--36 VDC to 5 VDC. The only voltage required by the rest of the circuitry is 5 V. The fiber optic receiver section converts the optical signal from the receiving optical fiber to a digital signal that is passed to the Communications section. The fiber optic transmitter section converts the digital signal provided by the Communications section into an optical signal on the transmitting optical fiber. The RS-485/Digital communications section coverts the input RS-485 signal from the twisted pair communication line to a digital signal used by the transmitter section. It also converts the digital signal from the receiver to a RS-485 signal for output on the communication line. It provides RS-485 isolation to eliminate line contention between the transmitter and receiver sections. RS3: Multipoint I/O Communication Devices SV: 6-2-14 Fiber Optic I/O Converter Power Wiring CAUTION The panel must be connected to a good earth ground. It is mounted to the DIN rail by nonconducting plastic feet. The connection for chassis ground is on the power strip (TB3). The power jack (J980) is a four-position locking connector and is compatible with the 30 V bus cable used in other parts of the system. It provides for 30 V A and B supplies, thereby allowing for redundant power connections. Figure 6.2.8 shows this usage. NOTE: Use either the power jack or the power strip. Do not use both. A B RTN J980 A B RTN A B RTN TB3 B Return A Return B Supply A Supply Standard A and B Power Supply Cable Figure 6.2.8. Power and Ground Wiring: Using the Power Jack The power strip (TB3) is a screw down terminal block style connector. It provides two inputs for 30 V A and B supplies. This allows for easy daisy chaining of power. The maximum current through the terminal block is 7 amps. Figure 6.2.9 shows this usage. A B RTN A B RTN TB3 A+ A -B+ B -- A -A+ B -B+ Daisy chain to next device NOTE: Maximum current (A + B) 7 amps Figure 6.2.9. Power and Ground Wiring: Using the Power strip RS3: Multipoint I/O Communication Devices SV: 6-2-15 Fiber Optic I/O Converter Communications Wiring The communication line at either end of the fiber optic link must not exceed 75 meters (300 feet) in length. The converter handles one communication line that should be connected to TB1. The second jack (TB2) is provided to allow daisy chaining of the communication line to other devices. Three-position communication line connectors (50P05890103 or G53373--0103) are used. Connect the shield (or drain) to “S”, the black wire to “--”, and the red wire to “+” as shown in Figure 6.2.10. + -- Red Black S Shield Figure 6.2.10. Communication Line Connector Wiring Fiber Optic I/O Converter Fiber Optic Link Standard fiber optic cable is used. The transmitter and receiver connectors are bayonet type ST. See Site Preparation and Installation Manual (SP) for fiber optic cable installation and testing details. Transmit (T) of the unit nearest the ControlFile must connect to Receive (R) on the distant unit. The receive (R) of the near unit must connect to Transmit (T) on the distant unit. RS3: Multipoint I/O Communication Devices SV: 6-2-16 Fiber Optic I/O Converter LEDs There are three LEDs on the converter. Table 6.2.4 shows details. Table 6.2.4. Fiber Optic I/O Converter LEDs RS3: Multipoint I/O LED Color Function 5V POWER Green ON when power is ON. RECEIVE DATA Yellow Flashes when the unit is receiving data. TRANSMIT DATA Yellow Flashes when the unit is transmitting data. Communication Devices SV: 6-3-1 Section 3: Multipoint Discrete I/O (MDIO) This section covers the: D Direct Discrete Termination Panel II — D (Original) 1984--4127--000x Multi-FIM Discrete Termination Panel 1984--4282--000x — D D Isolated Discrete Termination Panel (pair) — Panel A 1984--4121--000x — Panel B 1984--4124--000x High Density Isolated Discrete Termination Panel 1984--4167--000x — D Standard Remote Termination Panel 1984--4344--000x — D 10P52700001 Direct Discrete Termination Panel — D (CE approved) Discrete Field Interface Module (FIM) — MDIOH High-side switching FIM (CE approved) 10P53550006 — MDIOL Low-side switching FIM (CE approved) 10P53520006 — MDIO Low-side switching FIM (Original) 1984--4080--000x NOTE: A high-side switching Field Interface Module (FIM) breaks the supply side of the circuit; a low-side switching FIM breaks the return side of the circuit. Multipoint Discrete I/O is used to read and control discrete (contact) I/O points. It allows location of the I/O electronics (FIM) at the field wiring termination panel. The Discrete Termination Panels may be mounted where the user desires (within communication wiring length limits). RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-2 The Direct Discrete, the Multi-FIM, and the Isolated Discrete Termination Panels provide the option of online replacement or redundant FIM operation. For an online replacement operation, a single FIM is installed and a single communication line is used. If this FIM fails, a replacement may be inserted in the empty socket. The replacement will take over for the failed FIM. Redundant operation requires two installed FIMs, two communication lines, and use of a Redundant I/O Block (RIOB). Both FIMs operate continuously, with one as primary, and the other as secondary. If the primary FIM fails, the secondary FIM takes over immediately. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-3 Direct Discrete Termination Panels There are two versions of the panel: D Direct Discrete Termination Panel II — D 10P 5270 0001 For use with high or low-side switching FIMs. CE approved. Direct Discrete Termination Panel — 1984--4127--000x Only for use with low-side switching FIMs NOTE: A high-side switching FIM breaks the supply side of the circuit; a low-side switching FIM breaks the return side of the circuit. Table 6.3.1 shows the parts replacement options. Table 6.3.1. Parts Replacement for the Direct Discrete Termination Panel Part No. Replaces Name on PWA Characteristics 10P 5270 0001 1984--4127--000x DIRECT DISCRETE TERMINATION PANEL II Use only the MDIOL Low-Side Switch FIM to ensure compatability. 10P 5270 0001 DIRECT DISCRETE TERMINATION PNL 1984--4127--000x RS3: Multipoint I/O Valid replacement only for non-CE installations that use the MDIOL Low-Side Switch FIM. Multipoint Discrete I/O (MDIO) SV: 6-3-4 Direct Discrete Termination Panel II The Direct Discrete Termination Panel II (10P 5270 0001) is CE approved for installations conforming to the CE EMC directives. It can hold either a high-side switching FIM (MDIOH) or a low-side switching FIM (MDIOL or MDIO). The panel keying can be changed to prevent insertion of a FIM that is wrong for the installation. Figure 6.3.2 shows the panel. FIMs The High-Side Switch FIM (MDIOH) breaks the high (supply) side of the circuit for outputs. This FIM should be used for all new installations. The Low-Side Switch FIM (MDIOL) breaks the low (return) side. This FIM is used primarily for installations that are backward compatible with the earlier MDIO FIM (1984--4080--0001). I/O Points The panel supports 16 input/output points (1--16) and 16 input-only points (17--32). D All points share a common return bus which is floating relative to the panel chassis ground. D Points 1--16 can be configured as inputs or as outputs. D Points 17--32 can only be configured as inputs. D D Point 1 must be configured (either as input or output) and the transition voltage must be specified. The transition voltage applies to all 32 points. See the I/O Block Configuration Manual (IO:10). For most applications, FRSI recommends that VTH = ½Vsource (Figure 6.3.1). For an input point with VTH = ½Vsource, the resistance to Vsource of the field device in the ON state must be 1400 Ω or less to ensure positive turn-ON. The resistance to Vsource of the field device in the OFF state must be 3200 Ω or greater to ensure positive turn-OFF. Vsource Rs where 1) Rs=Resistance of field device 2) VTH=Threshold Voltage 3) Vsource=voltage powering the loop To FIM Figure 6.3.1. Recommended Resistance Loop Power A source of loop power is required unless all points are voltage inputs. The source must not exceed 36 Volts. D RS3: Multipoint I/O Each group of 8 points can have an independent source of loop power but all sources must share the common return bus. The panel is normally shipped with all voltage terminals (V1--V4) and their returns (N1--N4) jumpered together. Multipoint Discrete I/O (MDIO) SV: 6-3-5 D Voltage source inputs must have their returns connected to the loop power return. CAUTION Do not use the same source to power the panel and to supply loop power. This bypasses power isolation and can result in field wiring faults propagating to the power source. NOTE: Removing power from the panel stops processing for all 32 points. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-6 9 8 10 11 12 7 13 2 3 14 15 16 6 17 18 5 19 4 20 3 21 2 22 23 1 RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-7 Description No. No. Description 1 HD17 Address Jumper 13 F25--F32 Fuses for input points 25--32 2 Polarizing plug for MDIOH FIM 14 TB7 Field wiring for input points 25--32 3 Polarizing plug for MDIOL FIM 15 TB5 V3 for input points 17--24 and V4 for input points 25--32 4 HD1--HD16 Point Selection Jumpers for input/output points 1--16 16 F17--F24 Fuses for input points 17--24 5 FIM A (required) 17 TB5 Field wiring for input points 17--24 6 Socket for FIM B (optional for redundancy) 18 TB2 V2 for input/output points 9--16 and V3 for input points 17--24 7 Port B Communications (for redundancy) 19 TB3 Field wiring for input/output points 9--16 8 Port A Communications (required) 20 F9--F16 Fuses for input/output points 9--16 9 J968 Power Jack 21 10 HD18 Redundancy Jumper 22 F1--F8 Fuses for input/output points 1--8 11 TBA Power Strip 23 TB1 Field wiring for input/output points 1--8 12 Spare polarizing plugs TB2 V1 for input/output points 1--8 and V2 for input/output points 9--16 Figure 6.3.2. Direct Discrete Termination Panel II (10P 5270 0001) RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-8 Direct Discrete Termination Panel II Installation See 6-1-1, “Multipoint I/O Installation and System Wiring”, for installation, panel addressing, power wiring, communication wiring, redundancy, and online replacement information. Keying Panels and FIMs are keyed to prevent insertion of the wrong FIM type. The FIM has a pair of keying pins that fit into matching holes in the panel. The panel is set up by inserting plugs into the unused holes at each end of the FIM. Figure 6.3.3 shows a panel set up for a MDIOH FIM. Two spare plugs are provided with each panel. FIM A PLUG FOR MDIOH PLUG FOR MDIOL Figure 6.3.3. Direct Discrete Termination Panel II Keying - To remove a plug: 1. Insert a screwdriver under the lip of the plug. The small access hole at the edge of the plug can be used to get the screwdriver under the plug. 2. Pry the plug up until you can grip it with you fingers and pull it out. - To insert a plug: 1. Press the plug into the hole until it clicks in place. Be sure to use the marked hole rather than the nearby access hole. 2. Repeat for the other end of the FIM. Labels A replaceable label (1984--4195--0001) is provided on top of the termination panel label holder assembly. The label provides space at the end to record the ControlFile Node address, Controller Slot Address, Termination Panel (FIM) address, and Communication Line. The body of the label provides for recording each point’s field connection and the source of external loop power (V+, V--). A label on the underside of the label holder shows wiring examples. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-9 Direct Discrete Termination Panel II Field Wiring The panel supports 32 I/O points in four groups of eight points. Each has a group supply bus (V). All groups share a common return bus (N). The supplies (V1--V4) are isolated so that each group may be powered independently (as long as the returns can be common). The terminals will accommodate wire sized 4 to 0.34 mm2 (12 to 22 AWG). Loop Power The panel is normally shipped with all supply (V1--V4) terminals jumpered together. Jumpers are also installed on all return (N1--N4) terminals (N) to carry excess current between the terminals. The jumpers on the return terminals (N) should not be removed. NOTE: The loop power return bus is isolated from chassis ground. You can supply a connection to the chassis ground terminal of TBA if it is required for your installation. Field Terminals Figure 6.3.4 shows the terminals for points 9--16. Note that the group supply line terminates at each end of the group. This makes it easy to daisy chain groups together. Output points and contact-closure input points are wired between the upper (odd) terminal and the corresponding lower (even) terminal. Voltage-input points are wired between the lower (even) terminal and the common return bus. 9 10 11 12 13 14 15 16 V1 V2 N1 N2 1 2 3 2 Description No. 4 No. V2 V3 N2 N3 1 5 2 2 Description 1 V2 Loop Power + (for points 9--16) 4 Points 9--16 return -- 2 Common Loop Power return bus 5 V3 Loop Power + (for points 17--14) 3 Points 9--16 supply + Figure 6.3.4. Direct Discrete Termination Panel II Field Terminals RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-10 Direct Discrete Termination Panel II Jumpers There are three sets of jumpers on the panel. HD17 specifies the panel (FIM) address. HD18 specifies normal single-FIM operation or optional redundant (two-FIM) operation. Jumpers HD1--HD16 change connections for points as shown on the following pages. Table 6.3.2 shows jumper settings. Table 6.3.2. Direct Discrete Termination Panel II Jumper Settings RS3: Multipoint I/O Jumper Setting HD1--HD16 Left (One jumper per point) Right Function MDIOL: Input or Output Point MDIOH: Input Point MDIOH: Output Point A Use Card Cage Address A HD17 B Use Card Cage Address B (One jumper) C Use Card Cage Address C D Use Card Cage Address D E Not used F Not used HD18 NORM Normal single-FIM operation (Two jumpers) REDUN Redundant operation with two FIMs Multipoint Discrete I/O (MDIO) SV: 6-3-11 Low-Side Switch FIM: Put the jumper at the left for all points. Contact Closure input Point 5 1 V+ V-- 1 2 2 No. 4 3 Voltage Input Point Description 1 V+ (Loop power supply) 2 Field terminal block (Odd number, upper row) 3 Input contact 4 Field terminal block (Next even number, lower row) 5 FIM input to A/D converter 1 V+ V-- No. 4 1 2 2 Description 1 FIM input (A/D converter) 2 Field terminal block (Next even number, lower row) 3 Voltage input source 4 Voltage input return (Connected to any point on the common return bus) No. Description 3 Output Point 5 V+ 1 2 V-- 1 2 4 3 RS3: Multipoint I/O 1 V+ (Loop power supply) 2 Field terminal block (Odd number, upper row) 3 Load 4 Field terminal block (Next even number, lower row) 5 FIM input (V-- switched return) Multipoint Discrete I/O (MDIO) SV: 6-3-12 High-Side Switch FIM: Put the jumper at the left for inputs and at the right for outputs. Contact Closure Input Point 5 V+ 2 1 No. V-- 1 2 4 3 Voltage Input Point Description 1 V+ (Loop power supply) 2 Field terminal block (Odd number, upper row) 3 Input contact 4 Field terminal block (Next even number, lower row) 5 FIM input (A/D converter) 1 V+ No. V-- 4 1 2 2 Description 1 FIM input (A/D converter) 2 Field terminal block (Odd number, upper row) 3 Voltage input source 4 Voltage input return (Connected to any point on the common return bus) No. Description 3 Output Point 1 V+ 2 V-- 5 1 2 4 3 RS3: Multipoint I/O 1 FIM output (Switched V+) 2 Field terminal block (Odd number, upper row) 3 Load 4 Field terminal block (Next even number, lower row) 5 V-- (Common return) Multipoint Discrete I/O (MDIO) SV: 6-3-13 Direct Discrete Termination Panel II Fuses The panel is supplied with a 1.6-amp fuse in each circuit as shown in Table 6.3.3. Do not use larger fuses; smaller fuses can be used if desired. Jumpers HD1--HD16 place the fuse in the powered side of the 16 I/O points. Fuses 17--32 are always on the powered side of the input-only points. NOTE: The fuse is out of the circuit when voltage inputs are used. Table 6.3.3. Direct Discrete Termination Panel II Fuses Fuse FRSI Part No. Littelfuse Part No. Wickman Part No. Characteristics F1 to F32 G53394--1000--0005 216 001 19 194 1A 1 A 250 V (IEC) Quick action 5x20 mm Ceramic RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-14 Direct Discrete Termination Panel The Direct Discrete Termination Panel (1984--4127--000x) is marked “DIRECT DISCRETE TERMINATION PNL” on the Printed Wiring Assembly (PWA). This panel handles 32 points: 16 input/output points and 16 input-only points. The Direct Discrete Termination Panel (1984--4127--000x) can hold only low-side switching FIMs (MDIOL or MDIO). One FIM must be installed, the second is required only for redundant operation. NOTE: Removing power from the panel stops processing for all 32 points. Figure 6.3.5 shows the Direct Discrete Termination Panel. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-15 ADDRESS/COMM RATE A BCDEF HD1 Power Jack STATUS LEDS FIM A THIS END J968 STATUS LEDS FIM B F1 F3 F2 F5 F4 F7 F6 F9 F11 F13 F15 F8 F10 F12 F14 F16 THIS END F17 F19 F21 F23 F25 F27 F29 F31 F18 F20 F22 F24 F26 F28 F30 F32 TBA TB1 TB3 TB5 TB4 TB2 TBC TB7 FIM POWER TB6 Power Strip NOTE: These variations exist for HD2: Two three-position headers Two two-position headers Two wires soldered in place TBB HD2 AB See text for jumper usage CLIP FOR MODULE REDUNDANCY HD2 NORM A B FIM REDUND Figure 6.3.5. Direct Discrete Termination Panel RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-16 Direct Discrete Termination Panel Installation See 6-1-1, “Multipoint I/O Installation and System Wiring”, for installation, panel addressing, power wiring, communication wiring, redundancy, and online replacement information. Direct Discrete Termination Panel Field Wiring The panel supports 32 I/O points in four groups of eight points. Each has a group supply bus. All groups share a common neutral bus. The supplies are isolated so that each group may be used as desired (as long as the neutrals can be common). The terminals will accommodate one wire sized 4 to 0.34 mm2 (12 to 22 AWG). NOTE: The neutral line is isolated from chassis ground. You must supply the connection to chassis ground. For most applications, FRSI recommends that VTH = ½Vsource (Figure 6.3.1). For an input point with VTH = ½Vsource, the resistance to Vsource of the field device in the ON state must be 1400 Ω or less to ensure positive turn-ON. The resistance to Vsource of the field device in the OFF state must be 3200 Ω or greater to ensure positive turn-OFF. Figure 6.3.6 shows a pictorial representation and a circuit diagram of a typical group. Note that the group supply line terminates at each end of the group. This makes it easy to daisy chain groups together. The panel is shipped with all of the group supplies jumpered together (all 1--2 terminals connected). Jumpers are installed on all neutral terminals (3--4) to carry excess current between the terminals. CAUTION The jumpers on terminals 3-- 4 should not be removed. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-17 1 1 2 3 3 5 7 9 11 13 15 4 2 4 6 1 2 1 2 3 4 8 10 12 14 16 Side View 1 2 Group Supply Bus 1 15 2 16 FIM Interface 3 4 Common Neutral Bus 3 4 Figure 6.3.6. Direct Discrete Termination Panel Field Wiring Connections RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-18 Direct Discrete A replaceable label (1984--4195--0001), Figure 6.3.7, is provided on the Termination Panel Direct Termination Panel label holder assembly. The label provides Field Wiring spaces at the end to record the ControlFile Node address (1--32), Controller Slot Address (A--H), Termination Panel (FIM) address (A--D), and Communication Line (1--8). There is provision for recording both the primary and redundant communication line addresses. The body of the label provides for recording the group supply sources (V1--V4) and each point’s field connection (1--32). Labels 1 2 3 4 5 6 7 8 V1 V2 9 10 11 12 13 14 15 16 V2 V3 17 18 19 20 21 22 23 24 V3 V4 25 26 27 28 29 30 31 32 CF NODE CNTRLR TP ADDR COMM PRIM RED Figure 6.3.7. Label for Direct Discrete Termination Field Wiring The underside of the label holder carries a replaceable label (1984--4196--0001). This label shows a schematic of the field wiring terminations and provides space for recording fuse values. Figure 6.3.8 shows the schematic and relates it to the panel circuit diagram. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-19 F17 F18 F19 F20 F21 F22 F23 F24 V2 V3 1 TB5 2 TB4 3 4 COMMON INPUT POINT V3 V3 V3 V3 V3 V3 V3 V3 V3 V4 1 1 3 5 7 2 4 6 + + + 17 18 19 9 11 8 10 + + 13 15 12 14 16 + + 20 21 22 23 2 TB6 3 4 + COMMON 24 INPUT POINT TBA TBB + -- S + -- S TBC A B RTN A B RTN TH + + -- -- + + -- -- GROUND FIM POWER 24--30 VDC REDUNDANT BUSES A AND B Figure 6.3.8. Label for the Direct Discrete Termination Panel RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-20 Direct Discrete Figure 6.3.9 shows how to wire output points (1--16). Termination Panel Field Wiring Point 1 has been wired to use the group supply to feed FIM Pt 1. The field load will be ON when FIM Pt 1 is ON. Output Points NOTE: The FIM interface is on the low side of the load, therefore this is a low-side switching device. Direct Discrete Figure 6.3.9 also shows two ways to wire input points (1--32). Termination Panel Field Wiring Point 3 has been wired to use the group supply to feed FIM Pt 3. FIM Pt 3 will go ON when the field contact is closed. Input Points Point 8 has been wired to use a field-supplied voltage. FIM Pt 8 will go ON when the field wiring circuit supplies signal voltage. 1 1 2 3 3 5 7 9 11 13 15 4 2 4 6 1 2 1 2 3 4 8 10 12 14 16 Side View 1 2 Group Supply Bus 1 Field Load Field Contact 15 2 Field Contact and Supply 16 + -- FIM Interface 3 4 1 2 3 4 5 6 7 Common Neutral Bus 8 3 4 Figure 6.3.9. Direct Discrete Termination Panel Field Wiring Connections RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-21 Direct Discrete Termination Panel Jumpers Jumper HD1 specifies the termination panel (FIM) address. The slot address is specified by the communication line used. The factory sets HD1 for FIM address A. There is a jumper in position F. The jumper at F is reserved for a future application. The jumpers at HD2 specify normal or redundant operation of the panel. The jumpers must be removed to allow FIM redundancy. Table 6.3.4 shows jumper values. Table 6.3.4. Direct Discrete Termination Panel Jumpers Jumper HD1 HD2 RS3: Multipoint I/O Value Effect A FIM address A (factory setting) B FIM address B C FIM address C D FIM address D E Not used F Factory setting, do not move Both Jumpers ON or both jumpers at NORM or both wires intact Normal single FIM operation with online replacement capability Both Jumpers OFF or both jumpers at FIM REDUND or both wires cut Redundant FIM operation Multipoint Discrete I/O (MDIO) SV: 6-3-22 Direct Discrete Termination Panel Fuses There are 32 fuses protecting the signal circuits. The factory installs 1-amp fuses in all positions. Other fuses appropriate for the load to be protected may be installed but must not exceed a 1.0 amp rating (IEC) or 1.6 amp (UL/CSA). If other fuses are installed, the fuse rating should be marked on the point’s data label. Table 6.3.5 shows fuse data. Table 6.3.5. Direct Discrete Termination Panel Fuses Fuse FRSI Part No. Littelfuse Part No. Wickman Part No. Characteristics F1 to F32 G53394--1000--0005 216 001 19 194 1A 1 A 250 V (IEC) Quick action 5x20 mm Ceramic RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-23 Multi-FIM Discrete Termination Panel The Multi-FIM Discrete Termination Panel (1984--4282--000x) holds three Discrete FIMs and provides marshaling panel connections for three sets of 32 I/O points. It is marked “MULTI-FIM TERMINATION PANEL” on the PWA. There are no fuses supplied for the field wiring. The panel may be used in three ways: 1. With three independent (nonredundant) FIMs. 2. With FIM A and FIM B as a redundant pair and FIM C as a stand-alone (nonredundant) FIM. FIM A will be the primary and FIM B will be the secondary. 3. With FIM A and FIM B as an online replacement pair and FIM C as a stand-alone (nonredundant) FIM. Only one FIM is required in either the A or B position. The other position is then available for an online replacement. The Multi-FIM Discrete Termination Panel can hold only low-side switching FIMs (MDIOL or MDIO). NOTE: Removing power from the panel stops processing for all three sets of 32 points. Figure 6.3.10 shows the Multi-FIM Isolated Discrete Termination Panel. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-24 J582 Communication Port B J583 Communication Port C HD12 Communication Line Connections Jumper TBA Power Strip J973 Power Jack J581 Communication Port A HD11 FIM C Direct/Isolated Jumper HD4 through HD8 Redundancy / Online Replacement Jumpers for FIM A and B J579 FIM C Points 1--16 (Input and Output) J580 FIM C Points 17--32 (Input Only) HD10 FIM B Direct/Isolated Jumper FIM A FIM B J577 FIM B Points 1--16 (Input and Output) FIM C J578 FIM B Points 17--32 (Input Only) HD9 FIM A Direct/Isolated Jumper J576 FIM A Points 17--32 (Input Only) J575 FIM A Points 1--16 (Input and Output) HD1, 2, 3 Address Jumpers for FIM A, B, C Labels for FIM Addresses Figure 6.3.10. Multi-FIM Isolated Discrete Termination Panel RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-25 The Multi-FIM Discrete Termination Panel can be connected to up to six Standard Remote Termination Panels by marshalling panel cables. Use the 1984--4299--xxxx cable for single FIM applications and the 1984--4319--xxxx cable for redundant FIM applications. Figure 6.3.11 shows connections for an application using FIMs A and B as a redundant pair and FIM C as a single FIM. Field wiring is landed on a Standard Remote Termination Panel. Wiring methods are identical to those used for the Direct Discrete Termination Panel. See the write-up on that panel for details. 1984--4299--xxxx single FIM cables FIM C Points 1--16 (Input and Output) FIM C Points 17--32 (Input Only) Redundant FIM A/B Points 1--16 (Input and Output) 1984--4319--xxxx redundant FIM cables Redundant FIM A/B Points 17--32 (Input Only) Figure 6.3.11. Field Wiring to a Multi-FIM Discrete Termination Panel Multi-FIM Discrete Termination Panel Label Label holders are provided by jumper positions HD1, 2, and 3 to record the address of FIMs A, B, and C. Write the FIM address on the label next to the FIM. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-26 Multi-FIM Discrete Termination Panel Jumpers Jumpers HD1, HD2, and HD3 specify the termination panel address (A, B, C, or D) for FIMs A, B, and C. The address should be set to A whenever possible to get the highest scan rate. The factory sets each FIM for address A. Only one jumper is allowed in positions A--D. There is also a jumper in position F; this is reserved for a future application. Jumpers HD4 through HD8 control redundancy or online replacement operation of FIMs A and B. Unused jumpers may be “parked” at 1--2 for normal operation or all placed to 2--3 for redundant FIM operation. Jumpers HD9, HD10, and HD11 provide a return path for the loop or supply power for Intrinsically Safe barriers. Only two configurations are allowed, any other may cause damage to the FIM. CAUTION Remove power from the panel before moving the jumpers on HD9, 10, or 11. The FIM may be damaged if 1-- 8 is ON when any of the other positions are ON. For normal loop operation, install the three jumpers in positions 2--7, 3--6, and 4--5 (1--8 is open). For use with Intrinsically Safe barriers, only 1--8 is installed. The other two jumpers can be parked by placing them horizontally across the other pins as shown on the PWA. Jumper HD12 allows for the connection of communication ports A and B to support online replacement of FIMs A and B. For normal operation, all jumpers are removed from HD12. For online replacement of FIMs A and B, jumpers are placed on 1--12, 3--10, and 5--6. Table 6.3.6 shows jumper values. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-27 Table 6.3.6. Multi-FIM Discrete Termination Panel Jumpers Jumper Value A ON HD1, 2, 3 HD4--8 HD9, 10, 11 RS3: Multipoint I/O FIM address A (factory setting) NOTE: Only one jumper is allowed in positions A--D B ON FIM address B C ON FIM address C D ON FIM address D E OFF Not used F ON Factory setting, do not move 1--2 Normal individual FIM operation 2--3 Redundant operation of FIMs A and B 1--8 OFF 2--7 ON 3--6 ON 4--5 ON Normal loop operation 1--8 ON 2--7 OFF 3--6 OFF 4--5 OFF HD12 Effect Used with Intrinsically Safe barriers CAUTION Remove power from the panel before moving jumpers on HD9, 10, or 11. The FIM may be damaged if 1--8 is ON when any of the other positions are ON. OFF No jumpers) Communication Ports A and B are independent (normal operation of FIMs A and B) 1--12 ON 3--10 ON 5--6 ON Communication Ports A and B are connected (online replacement operation of FIMs A and B) Multipoint Discrete I/O (MDIO) SV: 6-3-28 Isolated Discrete Termination Panel The Isolated Discrete Termination Panel set consists of two panels normally connected by a flat ribbon cable. The pair services 32 discrete I/O points. The “A” panel supports 16 input/output points (1--16). The “B” panel supports 16 input-only points (17--32). Solid state relay modules are used for input and output control. The “A” panel (1984--4121--000x) is marked “ISOLATED DISCRETE TERMINATION PANEL A” on the PWA. The “B” panel (1984--4124--000x) is marked “ISOLATED DISCRETE TERMINATION PANEL B” on the PWA. The “B” panel must always be used in conjunction with an “A” panel because there is no provision for connecting a communication line to the “B” panel. The panels are normally connected by a (1984--4186--00xx) flat cable. An “A” panel may be used alone if no more than 16 points are required and the online replacement feature is not required. Each panel has a socket for one low-side switching FIM (MDIOL or MDIO). Either socket may be used for a single FIM. The socket on the other panel is then available for an online replacement if needed. For redundant operation, the primary FIM is inserted in the “FIM A” socket (“A” panel) and the redundant FIM is inserted in the “FIM B” socket (“B” panel). Both termination panels must be mounted with the long dimension vertical to allow cooling of the solid state relays by natural air convection. The panels can be mounted with the “A” panel at the top and the “B” panel directly below. The panels are connected using a short (1984--4186--00xx) flat cable. The panels can also be mounted side by side using a round cable no more than 152 cm (5 feet) long. Cable 1984--0498--0005 can be used. NOTE: Removing power from the panel stops processing for all 32 points. CAUTION The solid state relays may be hot enough to cause burns. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-29 Figure 6.3.12 shows Isolated Discrete Termination Panel A. ADDRESS / COMM RATE A B C D E F HD1 STATUS LEDS FIM A THIS END SSR2 SSR4 SSR6 SSR8 SSR10 SSR12 SSR14 SSR16 J564 SSR1 F1 F2 SSR3 F3 F4 SSR5 F5 F6 SSR7 F7 F8 SSR9 F9 TB3 TB1 SSR13 SSR15 F10 F11 F12 F13 F14 F15 F16 TB5 TB4 TB2 SSR11 TB7 TBA TBB TBC TB6 Power Strip NOTE: These variations exist for HD2: Two three-position headers Two two-position headers Two wires soldered in place HD2 AB See text for jumper usage CLIP FOR MODULE REDUNDANCY HD2 NORM A B FIM REDUND Figure 6.3.12. Isolated Discrete Termination Panel A RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-30 Figure 6.3.13 shows Isolated Discrete Termination Panel B. HD1 ADDRESS / COMM RATE A B C D E F HD1 STATUS LEDS FIM B THIS END SSR18 SSR20 SSR22 SSR24 SSR26 SSR28 SSR30 SSR32 Power Jack J565 SSR17 SSR19 SSR21 SSR23 SSR25 SSR27 SSR29 SSR31 J969 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 TB8 TB10 TB9 TB12 TB11 TBC TB14 1 2 TB13 Figure 6.3.13. Isolated Discrete Termination Panel B RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-31 Isolated Discrete Termination Panel Field Wiring Each panel supports 16 points in four groups of four points. Each group has a group supply line and a group return line. The groups are entirely isolated so that each group may be used as desired. The terminals will accommodate one wire sized 4 to 0.34 mm2 (12 to 22 AWG). NOTE: A ControlBlock must be configured for address 1 since the switch voltage for the entire FIM is set from the address 1 ContolBlock. set the swtich voltage at 1.7 Volts to ensure consistent switching. Figure 6.3.14 shows a pictorial representation and a circuit diagram of a typical group. Note that the group supply and group return lines terminate at each end of the group. This makes it easy to daisy chain groups together. The panels are shipped with all of the group supplies jumpered together (1--2) and the group returns jumpered together (3--4). The Solid State Relays (SSRs) are connected to terminals in each row (2--3, 6--7, 10--11, 14--15). They may be used with the group supply and return or individually. The A panel is shipped with All SSR “+” terminals jumpered to the group supply (1--3, 5--7, 9--11, 13--15) to make the SSRs available as output devices. The B panel is shipped with all SSR “--” terminals jumpered to the group return (2--4, 6--8, 10--12, 14--16) to make the SSRs available as input devices. NOTE: Rules for Low Voltage Directive (LVD) compliance are covered in the Site Preparation and Installation Manual (SP). RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-32 1 1 3 2 15 4 2 16 1 2 3 4 3 4 Top View 1 1 2 3 3 5 7 9 11 13 15 4 1 2 4 6 2 8 10 12 14 16 Side View Group Supply F9 2 1 3 1 V F10 3 SSR9+ 5 V F11 7 SSR10+ + 4 SSR9 13 11 SSR11+ V + + SSR10 SSR11 SSR12 -6 SSR10-- 1 8 N -10 12 SSR11-- N 2 15 SSR12+ + -2 4 SSR9-- N 9 V F12 3 -14 16 SSR12-- N Group Return Figure 6.3.14. Isolated Discrete Termination Panel Field Wiring Connections RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-33 Isolated Discrete Termination Panel Field Wiring Labels A replaceable label is provided on each Isolated Termination Panel assembly (1984--4195--0002 for panel “A”, and 1984--4195--0003 for panel “B”). Figure 6.3.15 shows the panel “A” label. The label provides spaces at the end to record the panel’s ControlFile Node address (1--32), Controller Slot Address (A--H), Termination Panel (Card Cage) address (A--D), and Communication Line (1--8). There is provision for recording both the Primary and Redundant communication line addresses. The body of the label provides for recording the group supply sources (V1--V4) and each point’s field connection (1--16, or 17--32). 1 2 3 4 V1 V2 5 6 7 8 V2 V3 9 10 11 12 V3 V4 13 14 15 16 CF NODE CNTRLR TP ADDR COMM PRIM RED Figure 6.3.15. Label for Isolated Discrete Termination Field Wiring Panel A The underside of the label holder carries a schematic of the field wiring terminations. Figure 6.3.16 shows the label for the “A” panel (1984--4196--0002) and relates it to the panel circuit diagram. Figure 6.3.17 shows the label for the “B” panel (1984--4196--0003). RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-34 Group Voltage 3 F9 F10 TB5--3 SSR9+ TB4--2 TB5--1 V3 TB5--7 SSR10+ TB5--5 V3 + TB4--4 F11 SSR10 TB5--4 N3 TB5--2 SSR9-- SSR11 -- -- -- TB5--8 N3 TB5--6 SSR10-- TB5--15 TB6--1 SSR12+ TB5--13 + V3 TB6--3 SSR12 TB5--11 SSR11+ TB5--9 + V3 + SSR9 F12 -- TB5--12 N3 TB5--10 SSR11-- TB5--14 SSR12-- TB5--16 N3 Group Return 3 F9 F10 F12 F11 F9 F10 F11 F12 V3 + V3 + V3 + V3 + 1 3 5 7 9 11 13 15 V3 V4 1 2 2 4 6 8 10 12 14 16 ---- N3 ---- N3 ---- N3 ---- N3 9 10 11 12 TB6 TB5 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 3 4 N3 N4 F11 F12 F13 F14 F15 F16 TBA TBB + -- S + -- S TBC A B RTN A B RTN + + -- -- + + -- -- TB1 TB2 TB3 TB4 TB5 TB6 TB7 GROUND FIM POWER 24--30 VDC REDUNDANT BUSES A AND B Figure 6.3.16. Label for Isolated Discrete Termination Panel A RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-35 F26 F28 F27 F25 F26 F27 F28 TB5 V3 + V3 + V3 + V3 + 1 3 5 7 9 11 13 15 V3 V4 1 2 2 4 6 8 10 12 14 16 ---- N3 ---- N3 ---- N3 ---- N3 25 F17 F18 F19 F20 F21 F22 F23 26 F24 27 F25 TB6 3 4 N3 N4 28 F26 F27 F28 F29 F30 F32 F31 GROUND Figure 6.3.17. Label for Isolated Discrete Termination Panel B RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-36 Isolated Discrete Termination Panel Field Wiring Output Points Output points are available only on panel A. The output Solid-State Relay acts as a switch. Figure 6.3.18 and Figure 6.3.19 show examples. System-Powered Output Point 1 3 -- + 2 5 4 No. Description No. Description 1 Fuse and group supply (terminals 1, 5, 9, 13) 4 Group return (terminals 4, 8, 12, 16) 2 Solid-State Relay -- (terminals 2, 6, 10, 14) 5 Output load 3 Solid-State Relay + (terminals 3, 7, 11, 15) Figure 6.3.18. System-Powered Output Point Wiring Field-Powered Output Point 1 3 -- + 2 5 No. 4 Description No. Description 1 Fuse and group supply (unused) 4 Group return (unused) 2 Solid-State Relay -- (terminals 2, 6, 10, 14) 5 Output load including power source 3 Solid-State Relay + (terminals 3, 7, 11, 15) Figure 6.3.19. Field-Powered Output Point Wiring RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-37 Isolated Discrete Termination Panel Field Wiring Input Points Input points are available on both panels. The input Solid-State Relay acts as a sensor. Figure 6.3.20 and Figure 6.3.21 show examples. Contact-Closure Input Point 1 3 5 -- + 2 4 No. Description No. Description 1 Fuse and group supply (terminals 1, 5, 9, 13) 4 Group return (terminals 4, 8, 12, 16) 2 Solid-State Relay -- (terminals 2, 6, 10, 14) 5 Input contact closure 3 Solid-State Relay + (terminals 3, 7, 11, 15) Figure 6.3.20. Contact-Closure Input Point Wiring Field-Powered Input Point 1 3 -- + 2 5 No. 4 Description No. Description 1 Fuse and group supply (unused) 4 Group return (unused) 2 Solid-State Relay -- (terminals 2, 6, 10, 14) 5 Input contact closure including power source 3 Solid-State Relay + (terminals 3, 7, 11, 15) Figure 6.3.21. Field-Powered Input Point Wiring RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-38 Isolated Discrete Termination Panel Solid State Relays Solid State Relays (G12243--00xx), also called Optical Isolator Modules, are solid-state, optically isolated relays that define each contact point as an input or an output. Care must be taken to make sure the proper type of module is installed because input and output modules are mechanically interchangeable. Table 6.3.7 lists the module types currently available. NOTE: AC inputs are yellow and outputs are black. DC inputs are white and outputs are red. Table 6.3.7. Solid State Relays Part Number C12243-- Model Function Output Contact* Voltage Color --0005 IAC5A AC Input None 180--280 VAC/VDC Yellow --0006 IDC5 DC Input None 10--32 VDC White --0007 IDC5--B IDC5--F DC Input None 4--16 VDC White --0008 IAC5 AC Input None 90--140 VAC/VDC Yellow --0009 ODC5 DC Output N.O. 5--60 VDC Red --0010 ODC5A DC Output N.O. 5--200 VDC Red --0011 OAC5A5 AC Output N.C. 24--280 VAC Black --0012 OAC5 AC Output N.O. 12--140 VAC Black --0013 OAC5--A OAC5--1 AC Output N.O. 24--280 VAC Black --0014 IDC5G IDC5N DC Input None 35--60 VAC/VDC White N.O. 100 VDC 130 VAC (Max switching current .5 A, 10 VA contact rating) --0015 * ODC5RM ORR5--1 Dry Contact Relay All output modules, except OAC5A5, have normally open (N.O.) outputs. The output contact is open when the block output is FALSE. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-39 Isolated Discrete Termination Panel Jumpers Jumper HD1 specifies the card cage address (A--D) of the termination panel. The slot address is specified by the communication line. The factory sets HD1 for card cage A. Positions E and F specify the communication rate used. Position F specifies the standard System 3 rate of 10.4 kb. This jumper should not be moved. NOTE: Both jumpers on HD1 must be set identically on panels “A” and “B”. Jumper HD2 on panel “A” specifies normal or redundant operation of both the “A” and “B” panels. Three variations exist, they all perform the same function: D Two 3-position headers D Two 2-position headers D Two 2-position headers with soldered in wires. Figure 6.3.12 and Figure 6.3.13 shows the jumper locations and variations. Table 6.3.8 shows jumper values. Table 6.3.8. Isolated Discrete Termination Panel A Jumpers Jumper HD1 (Panels “A” & “B”) HD2 (Panel “A” only) RS3: Multipoint I/O Value Effect A Card cage A (factory setting) B Card cage B C Card cage C D Card cage D E Not used F Factory setting, do not move Both Jumpers ON or both jumpers at NORM or both wires intact Normal single FIM operation with online replacement capability Both Jumpers OFF or both jumpers at FIM REDUND or both wires cut Redundant FIM operation Multipoint Discrete I/O (MDIO) SV: 6-3-40 Isolated Discrete Termination Panel Fuses There are 16 fuses on each panel to protect the field circuits. The factory installs 3.15-amp fuses (IEC) in all positions. Other fuses appropriate for the load being protected may be installed but must not exceed a 4 amp UL/CSA rating. If other fuses are installed, the fuse rating should be marked on the point’s data label. Table 6.3.9 shows fuse data. Table 6.3.9. Isolated Discrete Termination Panel Fuses Fuse FRSI Part No. Littelfuse Part No. Wickman Part No. Characteristics F1 to F32 G53394--3150--0005 216 3.15 19 194 3.15 A 3.15 A 250 V (IEC) Quick action 5x20 mm Ceramic WARNING Hazardous voltage may be present. Cock out and tag hazardous voltage circuits prior to servicing. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-41 High Density Isolated Discrete Termination Panel The High Density Isolated Discrete Termination Panel services 32 discrete I/O points: 16 input/output points (1--16) and 16 input-only points (17--32). Miniature solid state relay modules are used for input and output control. The panel (1984--4167--000x) is marked “HIGH DENSITY ISOLATED DISCRETE TERMINATION PANEL” on the PWA. The panel has a socket for one low-side switching FIM (MDIOL or MDIO). Neither online replacement nor redundant FIM operation is supported by this panel. There are no fuses supplied for the field wiring. NOTE: Removing power from the panel stops processing of all 32 points. Figure 6.3.22 shows the High Density Isolated Discrete Termination Panel. WARNING The solid state relays may be hot enough to cause serious burns. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-42 J591 Communication Port A J592 Communication Port B TBA Power Strip J970 Power Jack FIM Address Label Solid State Relay 32 Connector #2 (J560) Points 17--32 (Input Only) FIM Connector #1 (J559) Points 1--16 (Input and Output) Solid State Relay 1 HD1, Address Jumpers A--F Solid State Relay 4 Figure 6.3.22. High Density Isolated Discrete Termination Panel RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-43 High Density Isolated Discrete Termination Panel Field Wiring Field wiring is landed on a Standard Remote Termination Panel, which is connected to the termination panel with a marshaling panel cable. Figure 6.3.23 shows the cabling. Connector #1 (J559) supports input/output points 1--16. Connector #2 (J560) supports input points 17--32. Use Marshaling Panel Cable 1984--4298--xxxx for standard applications and 1984--4345--xxxx for NEC/CSA applications. NOTE: A ControlBlock must be configured for address 1 since the switch voltage for the entire FIM is set from the address 1 ContolBlock. set the swtich voltage at 1.7 Volts to ensure consistent switching. 1984--4298--xxxx Marshaling Panel Cable 1984--4298--xxxx Marshaling Panel Cable High Density Isolated Termination Panel Points 17--32 (Input Only) Points 1--16 (Input and Output) Standard Remote Termination Panel Figure 6.3.23. Field Wiring to a Multi-FIM Discrete Termination Panel NOTE: Rules for LVD compliance are covered in the Site Preparation and Installation Manual (SP). High Density Isolated Discrete Termination Panel Label A label holder is provided to record the address of the FIM. Write the FIM address on the label. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-44 High Density Isolated Discrete Termination Panel Jumpers Jumper HD1 specifies the termination panel address (A--D) of the panel. The slot address is specified by the communication line. The factory sets HD1 for address A. Positions E and F specify the communication rate used. Position F specifies the standard System 3 rate of 10.4 kB. This jumper should not be moved. Only two jumpers may be in place on HD1: one for the panel address and one in position F. Position 2--3 is ON. Position 1--2 is reserved for future use. Table 6.3.10 shows jumper values. Table 6.3.10. High Density Isolated Discrete Termination Panel Address Jumpers RS3: Multipoint I/O Position Effect A Termination panel address is A (factory setting) (2--3 is ON) B Termination panel address is B C Termination panel address is C D Termination panel address is D E Not used F Factory setting, do not move Multipoint Discrete I/O (MDIO) SV: 6-3-45 High Density Isolated Discrete Termination Panel Solid State Relays Miniature solid state relays, also called Optical Isolator Modules, (G60350--xxxx) are solid-state, optically isolated relays that define each contact point as an input or an output. Table 6.3.11 lists the module types currently available. NOTE: Care must be taken to make sure the proper type of module is installed because input and output modules are mechanically interchangeable. WARNING The solid state relays may be hot enough to cause serious burns. Table 6.3.11. High Density Isolated Discrete Termination Panel, Solid State Relays Part Number C60350-- Model Function Output Contact Voltage Color 0001 70M--IAC5--A AC Input None 180--280 VAC Yellow 0002 70M--IDC5 DC Input None 10--32 VDC White 0003 70M--IAC5 AC Input None 90--140 VAC Yellow 0004 70M--ODC5 DC output N.O. 5--60 VDC Red 0007 70M--OAC5--A AC output N.O. 24--280 VAC Black RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-46 Discrete Field Interface Module (FIM) Electronics for Discrete I/O are provided by the Discrete Field Interface Module (FIM), The FIM handles 32 I/O points. The first 16 points can be input or output. The remaining 16 points are input only. There are three models available: D D D 10P 5355 0006 MDIOH High-side switching FIM (CE approved) marked “DISCRETE FIELD INTERFACE MODULE: HIGH SIDE SWITCH” on the front label. 10P 5352 0006 MDIOL Low-side switching FIM (CE approved) marked “DISCRETE FIELD INTERFACE MODULE: LOW SIDE SWITCH” on the front label. 1984--4080--000x MDIO Original low-side switching FIM marked “DISCRETE FIELD INTERFACE MODULE” on the front label. NOTE: A high-side switching FIM breaks the supply side of the circuit; a low-side switching FIM breaks the return side of the circuit. Table 6.3.12 shows the parts replacement rules. Table 6.3.12. Parts Replacement for the Discrete Field Interface Module Part No. Replaces Name on Label 10P 5355 0006 None DISCRETE FIELD INTERFACE MODULE: HIGH SIDE SWITCH High-side switching FIM (CE approved) 10P 5352 0006 1984--4080--000x DISCRETE FIELD INTERFACE MODULE: LOW SIDE SWITCH Low-side switching FIM (CE approved) 1984--4080--000x 10P 5352 0006 DISCRETE FIELD INTERFACE MODULE RS3: Multipoint I/O Characteristics Low-side switching FIM Use only in non-CE approved installations Multipoint Discrete I/O (MDIO) SV: 6-3-47 The Discrete FIM may be used on a Discrete Termination Panel, either singly or as part of a redundant pair. When used singly, there is provision for replacement of a failed FIM by a online replacement. There are no field serviceable components inside the Discrete FIM case. All jumpering and fusing is handled on the discrete Field Termination Panel. The FIM case should not be opened. Figure 6.3.24 shows a block diagram of the Discrete Field Interface Module (FIM). BRAM MUX To/From Field or Solid State Relays Output Latches I/O Circuits Micro 68HC711 A/D Converter A/D = Analog to Digital BRAM = Battery Racked Random Access Memory MUX = LED Drivers Comm Circuits From Address Jumpers Communication Line LEDs Multiplexer Figure 6.3.24. Discrete Field Interface Module (FIM) Block Diagram RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-48 Discrete FIM Online Replacement Most discrete termination panels have sockets for two Discrete FIMs. The FIM may be installed in either socket. The other socket may be used for online replacement. If a FIM fails in any way, a good FIM may be plugged into the empty socket. The new FIM takes over from the installed FIM in a few seconds. The failed FIM can be removed for repair as soon as the new FIM’s green LED goes ON and the yellow “Comm Active” LED flashes. The new FIM may be left in service in that socket. The empty socket will provide for future online replacement. See the write-up on the particular Discrete Termination Panel for more information about online replacement operation. Discrete FIM Redundancy Redundancy requires the use of two FIMs, two communications lines (two adjacent addresses, one odd and one even), and removing the jumpers at HD2 on the Discrete Termination Panel. The FIM at the odd numbered address is considered “primary”; the FIM at the even numbered address is “secondary”. If the primary FIM fails, the secondary FIM takes over. Normally the failed FIM red LED goes ON and the green LED flashes. The failed FIM should be removed and replaced with a good FIM. As soon as the new A FIM powers up, it takes over from the secondary FIM and resumes the duties of the primary FIM. If the secondary FIM fails, the primary FIM continues to operate. Normally the failed FIM red LED goes ON and the green LED flashes. The failed FIM should be removed and replaced with a good FIM. As soon as the good FIM powers up, it resumes the duties of the secondary FIM. See the write-up on the particular Discrete Termination Panel for more information on redundancy. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-49 Discrete FIM Precision The analog to digital converter (A/D) within the Discrete FIM has a tolerance of ±5%. Thus a nominal switch reference voltage of 10 volts may lie anywhere within 9.5 and 10.5 volts. There is also a built-in histeresis of ±12.5%. Thus, with an actual 10 volt switch reference voltage, the circuit would come ON at 11.25 volts and go OFF at 8.75 volts. See the specification sheets for further details. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-50 Discrete FIM LEDs The Discrete FIM has 32 yellow I/O status LEDs, and a set of three FIM status LEDs. Figure 6.3.25 shows the FIM front panel. Table 6.3.13 explains the meaning of the LEDs. On: FIM Good Flashing: Inactive FIM Failure Comm Active DISCRETE FIELD INTERFACE MODULE INPUT ONLY POINTS INPUT / OUTPUT POINTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Figure 6.3.25. Discrete Field Interface Module (FIM) Table 6.3.13. MDIO, MDIOH, and MDIOL LEDs Meaning LED On: FIM Good Flashing: FIM Inactive (Green) FIM Failure (Red) Comm Active (Yellow) Input/Output Points 1--16 (Yellow) Input-Only Points 17--32 (Yellow) RS3: Multipoint I/O ON steady when the FIM is in normal operation. Flashing when the FIM is disconnected from the field. ON when FIM considers itself failed or when the FIM is not communicating with the Controller. Flashes when the FIM is communicating with the Controller Processor. Input: Output: ON for voltage above threshold or for a closed contact OFF otherwise ON when point is commanded ON OFF otherwise ON for voltage above threshold or for a closed contact OFF otherwise Multipoint Discrete I/O (MDIO) SV: 6-3-51 Discrete FIM LED Patterns When the FIM boots up, the red LED will go ON, the green LED will blink several times and then go ON. The red LED will go OFF, the green LED will go ON, and the yellow Comm Active LED will begin to flash rapidly as the FIM communicates with the Controller Processor. RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-3-52 RS3: Multipoint I/O Multipoint Discrete I/O (MDIO) SV: 6-4-1 Section 4: Multipoint Analog I/O (MAIO) This section covers the: D Multipoint Analog I/O Termination Panels — MAIO16 Serves 16 input or 16 output points, CE approved — MAIO Serves 16 input or 16 output points — MAI32 Serves 32 input points, CE approved D Loop Power Module (LPM) D Multipoint Analog I/O Field Interface Modules (FIMs) — MAI16 Serves 16 input points, CE approved — MAO16 Serves 16 output points, CE approved — MAIO Input Serves 16 input points — MAO Output Serves 16 output points — MAI32 Serves 32 input points, CE approved Multipoint Analog I/O (MAIO) is used to read and control analog I/O points. It allows placing the I/O electronics Field Interface Module (FIM) at the field wiring termination panel. The MAIO termination panels may be mounted where the user desires (within communication wiring length limits). The MAIO termination panels provide the option of online FIM replacement or redundant FIM operation. For online replacement operation a single FIM is installed and a single communication line is used. If this FIM fails, a replacement may be inserted in the empty socket. The replacement will take over for the failed FIM, which is then removed for repair. Redundant operation requires two installed FIMs, two communication lines, and use of a Redundant I/O Block (RIOB). Both FIMs operate continuously, with one as primary, and the other as secondary. If the primary FIM fails, the secondary FIM takes over immediately. Loop power can be supplied from an external source or from a Loop Power Module (LPM). The LPM produces up to 380 mA of DC current at 25.0 to 25.5 VDC. Externally supplied loop power must fall in the range 23--29 VDC. Because it might range outside the limit, do not use standard RS3 DC power. NOTE: Removing power from a termination panel stops processing of all points served by the panel. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-2 Multipoint Analog I/O Termination Panels These panels handle sixteen input points or sixteen output points, depending on the type of FIM that is installed: D D MAIO16 4--20 mA Termination Panel (CE approved): with field terminals 10P54770001 with field terminals and marshaling panel connector 10P54770002 MAIO 4--20 mA Termination Panel: with field terminals with field terminals and marshaling panel connector 1984--4383--0001 1984--4383--0002 This panel handles thirty-two input points: D MAI32 4--20 mA Termination Panel (CE approved): with field terminals 10P53490001 with field terminals and marshaling panel connector 10P53490002 Table 6.4.1 shows the parts replacement rules. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-3 Table 6.4.1. Multipoint Analog I/O Termination Panel Parts Replacement Part No. Replaces 10P54770002 10P54770001 MAIO16 Comments Only if marshaling cable is not used. 1984--4383--0001 Valid for all cases. 1984--4383--0002 Only if marshaling cable is not used. 10P54770001 Valid for all cases. 1984--4383--0001 Valid for all cases. 1984--4383--0002 Valid for all cases. 1984--4383--0001 MAIO 1984--4383--0002 Only if marshaling cable is not used. 1984--4383--0002 MAIO 1984--4383--0001 Valid for all cases. 10P53490001 MAI32 10P53490002 Only if marshaling cable is not used. 10P53490002 MAI32 10P53490001 Valid for all cases. 10P54770002 MAIO16 RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-4 MAIO16 Termination Panel The MAIO16 termination panel (10P5477000x) is available in two versions. It is marked “MAIO16 TERMINATION PANEL” on the PWA. This panel is CE approved when used with MAIO16 FIMs. D With field terminals 10P54770001 D With field terminals and marshaling panel connector 10P54770002 The panel can be used with these components: D Loop Power Module (LPM) D MAIO16 Field Interface Module (FIM): 4--20 mA Input 16 Point 4--20 mA Output 16 Point 1984--4398--0001 or 10P57070001 10P54040004 or 10P57700005 10P54080004 or 10P58080005 Figure 6.4.1 shows the panel. Table 6.4.2 lists the figure callouts. The panel can handle either 16 inputs or 16 outputs, depending on the type of FIM installed. One FIM must be installed; the second is required for redundant operation or for online replacement. Field wiring is landed directly on the --0001 panel using terminal blocks TB1 through TB16. A multiconductor cable and a remote marshaling panel is used with the --0002 panel to land the field wiring at a remote location. Loop power can be supplied by the user or by an optional Loop Power Module (LPM). There is a provision for a redundant Loop Power Module. Externally supplied loop power must fall in the range +23 to +29 VDC. CAUTION Do not use the RS3 DC bus as a source of loop power. The bus can exceed the limits of the loop power specification. NOTE: The length of the marshaling panel cable must be added to the field wiring cable length. The panel must be grounded by a solid connection to a grounded DIN rail, grounded mounting plate, or ground wire to the power strip ground terminal. A three-position terminal (+, --, and S) is used to connect field wiring to the panel. All of the field wire shields are connected together within the panel. TB18 provides a way to connect all field wire shields to the panel chassis ground or to leave them floating. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) 9 RS3: Multipoint I/O HD17 ADDRESS TB1 TB2 TB3 TB4 HD4 TB5 HD5 TB6 HD6 TB7 HD7 TB8 HD8 TB9 HD9 TB10 HD10 TB11 HD11 TB12 HD12 11 HD3 TB13 HD13 TB22 TB14 HD14 TB21 TB15 HD15 TB16 HD16 12 HD2 J597 TB17 TB18 17 HD1 TB20 16 TB19 LPM2 PORT B HD 18 N HD 19 R 15 FISHER--ROSEMOUNT FIM B 10 N R PORT A 13 FISHER--ROSEMOUNT PORT C SV: 6-4-5 1 2 14 3 4 5 6 17 7 8 Figure 6.4.1. MAIO16 Termination Panel Multipoint Analog I/O (MAIO) SV: 6-4-6 Table 6.4.2. MAIO16 Termination Panel Components No. Description No. 1 TBA Power Strip: For panel DC supply using stranded wire. Allows daisy chaining of DC power and access to panel chassis ground. 10 FIM A (J593): Input or Output FIM. 2 Power Jack (J974): For panel DC supply using a 1984--0158--xxxx cable. 11 FIM B (J594): Optional redundant Input or Output FIM. 3 TB18: Connects all field wiring shields (SH) to chassis ground (CH) when jumpered. 12 LPM 2 (J596): Optional second Loop Power Module. 4 TB17: External loop power terminal. V+ is loop power pos. V-- is loop power neg. 13 Port C (J598): Not used. 5 TB1--TB16: Field wiring terminals for points 1--16 (+, --, shield). 14 Port A (J599): Odd-numbered communication line for FIM A. 6 Marshaling panel connector (J597): Installed on --0002 panel only. 15 HD18--HD19: FIM redundancy jumpers. 7 HD1--HD16: Point Type jumpers. Control the supply of loop power to each field point. 16 Port B (J600): Even-numbered communication line for redundant FIM B. 8 LPM 1 (J595): Loop Power Module. 17 9 HD17 Panel (Card Cage) address (A, B, C, or D). RS3: Multipoint I/O Description Loop power supply jumpers TB19, TB20, TB21, and TB22. Jumper at TB21 shown in “holder” position. Jumper at TB22 shown in the “fully installed” position. position CAUTION: SEE Loop Power SECTION FOR INFORMATION ON PROPER PLACEMENT OF JUMPERS FOR ALL LOOP POWER OPTIONS. Multipoint Analog I/O (MAIO) SV: 6-4-7 MAIO16 Termination Panel Installation The termination panel is keyed to prevent installation of any other type of FIM. The keying does not prevent installing an input FIM when an output FIM is desired. An alarm will be generated if a Analog Input Block (AIB) finds an output FIM or an Analog Output Block (AOB) finds an input FIM. Checklist for CE Installation Follow these rules to ensure CE compliance: 1. Mount the termination panel in a properly grounded cabinet, on grounded DIN rails, or on a grounded mounting plate. 2. Use only FIMs bearing the 10P part number. Earlier FIMs with 1984 part numbers must not be used. 3. Use a Loop Power Module or a CE-approved source for external loop power. 4. Use shielded cable for field wiring. MAIO16 Termination Panel Loop Power A locally grounded source of loop power is required unless all points on the panel are self-powered inputs. Loop power can be supplied in any one of three ways: 1. Loop Power Module(s) (LPMs) This option is used when the FIM and loop power are supplied by the RS3 system DC bus or any DC supply that should be isolated from the field devices. In this case, loop power is derived from system power applied at TBA Power Strip through single or redundant LPM(s). A second LPM can be used to provide backup to the first LPM. When using one or two LPMs, remove all four jumpers at TB19 through TB22. Also, install a short wire jumper from the V-terminal of TB17 to the SH terminal of TB18 to provide a loop power ground reference; or leave a four-tab jumper connecting the V-- terminal of TB17 with the CH and SH terminals of TB18. 2. Combined FIM power and loop power This option is used when a DC power supply such as the Remote I/O Power Supply is located with the MAIO termination panel. A single supply or redundant pair of supplies powers both FIMs and loops. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-8 In this case, loop power comes directly from a suitable power supply (+24 to +28 VDC nominal) connected at TBA Power Strip through loop power jumpers TB19--TB22. For this option, all four jumpers at TB19 through TB22 must be in the “fully installed” position with both tabs of the jumper installed in the terminal block. The loop power supply must be ground referenced at its negative side. At no time may the loop power supply voltage exceed 29 VDC. 3. External Loop Power This option requires separate power wiring for FIM power and loop power. There is no provision for redundant loop supplies on the termination panel. In this case, a suitable power supply (+24 to +28 VDC nominal) is connected at external loop power terminal TB17. For this option, all four jumpers at TB19 through TB22 must be in the “holder” position with only one tab of the jumper installed in the terminal block. This prevents inappropriate installation of an LPM later. The loop power supply must be ground referenced at its negative side. At no time may the loop power supply voltage exceed 29 VDC. Loop power options 2 and 3 above require a ground referenced external supply. This ground reference must be at or near the termination panels. For supplies rated or fused at more than 7 Amps, the ground reference must be external to any termination panel, and TB17 V-terminal should not be jumpered to TB18 CH. Move the 4-tab jumper at TB17 and TB18, if installed, to the position where tabs are in TB18 only and one uninstalled tab is on each side of TB18. Smaller supplies, including the Remote I/O Power Supply, should be ground referenced at the termination panel by installing a wire jumper from TB17 V-- to TB18 SH, or leaving the 4-tab jumper connecting TB17 V-- to TB18 SH and TB18 CH. Loop Power modules provide well regulated loop power, which can be referenced to a local instrument ground. They provide a degree of fault isolation by serving a limited number of loops (up to 16) and by limiting the effects of any typical wiring fault on one of those loops to at most the loops served. Loop power modules can be used redundantly and can be connected to redundant system power. If the LPM is used with redundant FIMs, two LPMs are required. LPMs use the same system power source as the FIMs attached to the TBA Power Strip or the J974 Powerjack. Loop Power modules are used when no suitable external loop power supply is available or when fault isolation is required. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-9 Power applied at TBA Power Strip directly supplies loop power as well as FIM power when TB19, TB20, TB21, and TB22 are left in place. This supply must be in the +23 to +29 VDC range and must have its negative side grounded at the I/O cabinet that contains the termination panel. (RS3 system power supplies are not suitable for this purpose.) Some applications, such as with I.S. barriers, may require a voltage higher than +23 VDC. This method of providing loop power is typically used with a remote I/O cabinet that contains an AC-to-24 VDC or 28 VDC power supply. These power supplies may be redundant. An external +23 to +29 VDC supply may be connected to TB17 -External Loop Power Terminal. Redundant supplies are not directly supported. A power connection must still be made at the TBA Power Strip for FIM power. This approach is used when RS3 System power is available for Fim power and a separate supply is provided to power a large number of loops. CAUTION Jumpers at TB19, TB20, TB21, and TB22 must be removed before connecting power to TB17 or when using one or two Loop Power Modules. MAIO16 Termination Panel Field Wiring CAUTION Both signal wires of all input points must be constrained to operate within the common mode range +29 to - 2 VDC or erroneous results will be reported. The condition in the CAUTION is automatically met for all system powered inputs with an appropriate source of loop power. The ground reference is the V-- terminal of TB17. A self-powered input with a remote ground reference can operate with a ground differential of up to +/-- 2 VDC. A self-powered input with no other ground reference must be ground referenced at its point type jumper HD1 to HD16. Wire Landing Field wiring is landed at terminal blocks TB1--TB16 on the --0001 MAIO16 termination panel. A Remote Marshaling Panel and cable are used with the --0002 MAIO16 panel. The I/O Point Type jumpers (HD1--HD16) are used with both panels. Field wiring is landed as shown in Figure 6.4.2. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-10 --0001 --0002 Figure 6.4.2. MAIO16 Termination Panel Field Wire Landing Methods Shield Grounding All field wire shields are connected together and to TB18 SH at the termination panel. As shipped from the factory, TB18 SH and TB18 CH are tied together and newer panels also connect this to TB17 V--. This grounds shields and loop power negative to the chassis. In a few cases where the chassis ground is very noisy, the shields may need to be tied to a quieter ground. TB18 SH may be connected to this ground. If so, TB17 V-- should also be connected to the quieter ground. I/O Point Type Jumpers The ganged Point Type jumpers (HD1--HD16) are set to define each point. Each jumper can be set fully to the left, centered, or fully to the right. A point can be defined as: RS3: Multipoint I/O D Output D System-powered input D Self-powered input (with external ground reference) D Self-powered input (with ground reference at termination panel). Multipoint Analog I/O (MAIO) SV: 6-4-11 Output Point One of the three sources of loop power is required for output points. The Output FIM distributes the power to each point. All returns are connected to the loop power return. All Point Type jumpers (HD1--HD16) must be set to the full left position as shown in Figure 6.4.3. 1 --LP (all 16 pts) +LP (all 16 pts) +LP --LP 2 3 + -- S 4 No. Description No. Description 1 Output constant-current driver in FIM 3 Field wiring terminal block 2 Jumper at full left position 4 Valve or I/P Figure 6.4.3. MAIO16 Output Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-12 System-Powered Input Point A system-powered input point requires one of the three sources of loop power (described earlier). The Point Type jumper (HD1--HD16) must be set in the center as shown in Figure 6.4.4. 1 +LP --LP 2 3 + -- S 4 Description No. No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper centered 4 Transmitter Figure 6.4.4. MAIO16 System-Powered Input Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-13 Self-Powered Input Point with External Ground Reference A self-powered input point obtains its loop power from the transmitter or other device. The point can be isolated from the other points by placing the Point Type jumper (HD1--HD16) in the full left position as shown in Figure 6.4.5. This should be done only when the loop is ground referenced elsewhere in the loop, such as at the transmitter. Both the negative and positive sides of the loop must remain within the +29 VDC to --2 VDC range, relative to loop power negative TB17 V--. CAUTION The V-- terminal of TB17 must be tied to a suitable ground if Loop Power Modules are used. 1 +LP --LP 2 3 + -- S 4 Description No. No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper at full left position 4 Transmitter Figure 6.4.5. MAIO16 Self-Powered Input Point with External Ground Reference This configuration is useful when an additional device is placed in the loop between the negative terminal and ground, when a loop is referenced to a positive supply, or when the loop is ground referenced at a remote transmitter and there is some ground differential between the remote ground and local ground. The differential must be less than 2 VDC. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-14 Self-Powered Input Point with Ground Reference at Termination Panel A self-powered input point obtains its loop power from the transmitter or other device. The point can be referenced to the loop power return by placing the Point Type jumper (HD1--HD16) in the full right position as shown in Figure 6.4.6. This jumper position should be used when there is no other ground reference in a loop, such as when the loop is powered by a floating supply at the field device. 1 +LP --LP 2 3 + -- S 4 Description No. No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper at full right position 4 Transmitter Figure 6.4.6. MAIO16 Self-Powered Input Point with Ground Reference at Termination Panel RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-15 Marshaling Panel Cable The pin-out specification for the marshaling panel cable is shown in Table 6.4.3. Table 6.4.3. MAIO Marshaling Panel Cable Pin-Out Pin DIN # Signal Pin DIN # Signal Pin DIN # Signal Pin DIN # Signal 1 D2 1+ 10 D2 0 10+ 33 Z2 1-- 42 Z20 10-- 2 D4 2+ 11 D2 2 11+ 34 Z4 2-- 43 Z22 11-- 3 D6 3+ 12 D2 4 12+ 35 Z6 3-- 44 Z24 12-- 4 D8 4+ 13 D2 6 13+ 36 Z8 4-- 45 Z26 13-- 5 D1 0 5+ 14 D2 8 14+ 37 Z10 5-- 46 Z28 14-- 6 D1 2 6+ 15 D3 0 15+ 38 Z12 6-- 47 Z30 15-- 7 D1 4 7+ 16 D3 2 16+ 39 Z14 7-- 48 Z32 16-- 8 D1 6 8+ 17 B2-B30 Open 40 Z16 8-- 9 D1 8 9+ 18 B32 Shield 41 Z18 9-- MAIO16 Termination Panel Labels A replaceable label (1984--4195--0010) is provided on top of the termination panel label holder assembly. The label provides space at the end to record the ControlFile Node address, Controller Slot Address, Termination Panel (FIM) address (A--D), and Communication Line. There is provision to record both the primary and redundant communication line addresses. The body of the label provides for recording each point’s field connection (1--16) and the source of external loop power (V+, V--). RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-16 MAIO16 Termination Panel Jumpers All panel jumpers must be set for correct operation as shown in Table 6.4.4. Table 6.4.4. MAIO16 Termination Panel Jumpers Jumper Value Effect HD1--HD16 Full left Self-Powered Input Point with external ground reference or Output Point Centered System-Powered Input Point Full right Self-Powered Input Point with ground reference at termination panel A at 1--2 Cage address A (Factory setting) B at 1--2 Cage address B C at 1--2 Cage address C D at 1--2 Cage address D Both at “N” (1--2) Normal single FIM operation Both at “R” (2--3) Redundant FIM operation Requires two FIMs and two communication lines V--, SH & CH jumpered (4 tab jumper installed) Loop power negative and field wiring shields connected to chassis ground. Use with LPMs. (New factory setting.) SH to CH jumpered (4 tab jumper straddling TB18 or 2 tab jumper installed) Field wire shields connected to chassis ground. Use with locally grounded source of loop power. (Old factory setting with 2 tab jumper.) SH to CH open (Jumper removed) Allows connecting shield to a different ground reference than chassis. Jumpers fully installed, absent, or in ”holder for loop position”. Fully installed: Power at TBA used for loop power Holder position: Loop power connected at TB17 Absent: LPMs used for loop power HD17 HD18 HD19 TB18 TB19 TB20 TB21 TB22 MAIO16 Termination Panel Fuses There are no fuses on the panel. Current limiting is provided by the FIM. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-17 MAIO Termination Panel The MAIO termination panel (1984--4383--000x) is marked “MAIO TERMINATION PANEL” on the PWA. This panel handles 16 I/O points, with direct connection of I/O field wiring to the panel. There are two versions: D D 1984--4383--0001 with TB1--TB16 for the direct landing of field wires. 1984--4383--0002 with marshaling panel connector J597 for the remote landing of field wires on an MIO Marshaling Panel. The panel can handle either 16 inputs or 16 outputs, depending on the type of FIM installed. One FIM must be installed; the second is required for redundant operation or for online replacement. Loop power can be supplied by the user or by an optional Loop Power Module (LPM). There is a provision for a redundant Loop Power Module. Externally supplied loop power must fall in the range +23 to +29 VDC. CAUTION Do not use the RS3 DC bus as a source of loop power. The bus can exceed the limits of the loop power specification. Field wiring is landed directly on the --0001 panel. The --002 panel allows for both the direct landing of field wires and the use of a remote marshaling panel for landing field wires. NOTE: The length of the marshaling panel cable must be added to the field wiring cable length. The panel must be grounded by a solid connection to a grounded DIN rail, grounded mounting plate, or ground wire to the power strip ground terminal. Figure 6.4.7 shows the MAIO termination panel. One FIM and one Loop Power Module are shown installed. The --0001 panel is built with TB1--TB16; the marshaling connector J597 is not supplied. The --0002 panel has both TB1--TB16 and J597. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-18 POWER JACK POWER STRIP Loop Power Module TB10 TB11 TB12 TB13 TB14 TB15 TB16 Field Point 16 External Marshaling Panel Connector J597 (--0002 panel only) TB7 TB6 TB5 TB4 TB3 Field Wire Termination Points 1--16 TB2 HD4 HD2 HD1 ADDRESS TB1 HD8 HD6 HD7 HD5 HD3 LPM1 HD17 External Loop Power TB9 J597 HD9 FIM B FIM A HD10 HD11 FIM A Field Wire Shield Grounding TB8 HD12 HD13 LPM2 HD14 HD15 HD16 TB17 TB18 PORT B HD 18 N HD 19 R N R PORT A PORT C Communication Ports Power Jack Power Strip Redundancy Jumpers Field Point 1 Loop Power Jumpers Figure 6.4.7. MAIO Termination Panel RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-19 MAIO Termination Panel Installation See 6-1-1, “Multipoint I/O Installation and System Wiring”, for installation, panel addressing, power wiring, communication wiring, redundancy, and online replacement information. The termination panel is keyed to prevent installation of any other type of FIM. The keying does not prevent installing an input FIM when an output FIM is desired. An alarm will be generated if a Analog Input Block (AIB) finds an output FIM or an Analog Output Block (AOB) finds an input FIM. MAIO Termination Panel Loop Power Loop power for all points is supplied either by: D a Loop Power Module (LPM) on the panel D an external power source connected to TB17. The LPM draws power from the termination panel where it is installed and produces up to 380 mA of DC current at 25.0 to 25.5 VDC. Two LPMs can be used on a termination panel to provide backup operation in which one will supply the loop power if the other fails. They operate in a “hot standby” mode and do not significantly share the load. Using the LPM with redundant FIMs requires using two LPMs. An external DC source with nominal voltage from 24 to 28V can be connected to TB17 to provide loop power to all points. At no time may loop power voltage exceed 29 VDC. NOTE: Do not use both an LPM and an external power source. Do not draw power from TB17 when an LPM is used. Do not use the standard RS3 DC bus since the voltage can fall outside the limits. Distribution of loop power to each point is controlled by a per-point jumper (HD1--HD16). NOTE: All input points must be constrained to operate within the common mode range of +29 VDC to --2 VDC. This is automatic when all inputs are system powered. The ground levels must remain within ± 2 Volts of each other or erroneous results will be reported. The ground reference is available on TB17. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-20 MAIO Termination Panel Field Wiring The panel supports 16 analog I/O points. Field wiring may be landed directly on the --001 panel using TB1 through TB16. Cable connection on the --0002 panel uses a marshaling cable plugged into J597 and connected to an MIO Marshaling Panel where the field wiring is landed. A three-position terminal is used to connect field wiring to the panel. Each terminal is labeled +, --, and S for the plus and minus signal wires and the shield. The terminals will accommodate one wire sized 4 to 0.34 mm2 (12 to 22 AWG). All of the field wire shields are connected together on the panel. TB19 provides a way to connect all field wire shields to chassis ground or to leave them floating. The factory installs a wire from TB19 SH to CH, which connects all shields to panel chassis ground. Figure 6.4.8 shows the field I/O point circuit. A three-position ganged jumper is used to connect all but two of the pins. The jumper can be at one of three positions: full left, centered, or full right. FIM Input or output circuit +LP --LP Jumper Field Wiring + Terminal Block -- S Figure 6.4.8. Field I/O Point Circuit RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-21 MAIO Termination Panel Field Wiring - Output Points A source of loop power (described earlier) is required for output points. The Output FIM distributes the power to each point. All returns are connected to the loop power return. All Point Type jumpers (HD1--HD16) must be set to the full left position as shown in Figure 6.4.9. 1 --LP (all 16 pts) +LP (all 16 pts) +LP --LP 2 3 + -- S 4 No. Description No. Description 1 Output constant-current driver in FIM 3 Field wiring terminal block 2 Jumper at full left position 4 Valve or I/P Figure 6.4.9. Output Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-22 MAIO Termination Panel Field Wiring - Input Points A system-powered input point requires a source of loop power (described earlier). The Point Type jumper (HD1--HD16) must be set in the center as shown in Figure 6.4.10. 1 +LP --LP 2 3 + -- S 4 Description No. No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper centered 4 Transmitter Figure 6.4.10. System-Powered Input Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-23 Self-Powered Input Point (Isolated): A self-powered input point obtains its loop power from the transmitter or other device. The point can be isolated from the other points by placing the Point Type jumper (HD1--HD16) in the full left position as shown in Figure 6.4.11. This should be done only when the loop is ground referenced elsewhere in the loop, such as at the transmitter. Both the negative and positive sides of the loop must remain within the +29 VDC to --2 VDC range, relative to --LP at TB17. CAUTION TB17 must be tied to a suitable ground if Loop Power Modules are used and any points are configured as self-powered input point - isolated. 1 +LP --LP 2 3 + -- S 4 No. Description No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper at full left position 4 Transmitter Figure 6.4.11. Self-Powered Input Point (Isolated) This configuration is useful when an additional device is placed in the loop between the negative terminal and ground, when a loop is referenced to a positive supply, or when the loop is ground referenced at a remote transmitter and there is some ground differential between the remote ground and local ground. The differential must be less than 2 VDC. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-24 Self-Powered Input Point (Non-isolated): A self-powered input point obtains its loop power from the transmitter or other device. The point can be referenced to the loop power return by placing the Point Type jumper (HD1--HD16) in the full right position as shown in Figure 6.4.12. This jumper position should be used when there is no other ground reference in a loop, such as when one is powered by a floating supply. 1 +LP --LP 2 + 3 -- S 4 Description No. No. Description 1 Input sense resistor in FIM 3 Field wiring terminal block 2 Jumper at full right position 4 Transmitter Figure 6.4.12. Self-Powered Input Point (Referred to Loop Power Return: Non-isolated) RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-25 MAIO Termination Panel labels A replaceable label (1984--4195--0010), is provided on top of the termination panel label holder assembly. The label provides space at the end to record the ControlFile Node address (1--32), Controller Slot Address (A--H), Termination Panel (FIM) address (A--D), and Communication Line (1--8). There is space to record both the primary and redundant communication line addresses. The body of the label provides for recording each point’s field connection (1--16) and the source of external loop power (V+, V--). The underside of the label holder carries a label that shows jumper settings, communication line connections, and power connections. Figure 6.4.13 shows the labels. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) RS3: Multipoint I/O POINT 2 -- S TB2 -- S TB1 HD2 HD POINT 3 -- S TB3 POINT 4 -- S TB4 HD4 POINT 5 -- S TB5 HD5 POINT 6 -- S TB6 HD6 POINT 7 -- S TB7 HD7 POINT 8 -- S TB8 HD8 + TB9 POINT 9 -- S HD9 + HD12 HD13 POINT 10 POINT 11 POINT 12 -- S -- S -- S TB12 TB10 TB11 HD10 HD11 + POINT 13 POINT 14 -- S -- S TB13 TB14 HD14 HD15 + POINT 15 POINT 16 -- S -- S TB15 TB16 HD16 FIM/LPM DC POWER REDUNDANT SOURCES A AND B -- S PORT C REDUND EXT LOOP POWER V+ V-- GROUND/ SHIELD REF SH CH GROUND SEE SERVICE MANUAL A B RTN A B RTN TBA PORT B -- S COMMUNICATION CONNECTION -- S PORT A + + HD3 SINGLE FIM CONNECT ODD # COMM LINE TO PORT A REDUNDANT FIM CONNECT ODD # COMM LINE TO PORT A CONNECT EVEN # COMM LINE TO PORT B + POINT 1 HD1 JUMPER POSITION SYSTEM POWERED INPUTS LPM OR EXTERNAL LOOP POWERED SELF POWERED INPUTS OR SYSTEM POWERED OUTPUTS SELF POWERED INPUTS REFFERED TO LOOP POWER RETURN PRIMARY COMM LINE TP ADDRESS CONTROLLER CONTROLFILE NODE SV: 6-4-26 + + + + + + + + + + + + Figure 6.4.13. MAIO Termination Panel Labels Multipoint Analog I/O (MAIO) SV: 6-4-27 MAIO Termination Panel Jumpers Jumpers HD1 through HD16 control the supply of loop power to each I/O point. See “MAIO Termination Panel Field Wiring” on page 6-4-20. Jumper HD17 controls the card cage address of the termination panel. Legal addresses are A, B, C, or D. Jumpers HD18 and HD19 control single FIM or redundant FIM operation. Terminal block TB18 provides for grounding all field wiring shields to chassis ground when TB18 SH is jumpered to CH. The panel ships with this wire in place. When using Loop Power Modules, a short jumper wire must be installed from the V-terminal of TB17 to the SH terminal of TB18, in addition to the SH to CH jumper; or a 4-tab jumper may be used to connect all three terminals. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-28 Table 6.4.5. MAIO Termination Panel Jumpers Jumper HD1--HD16 HD17 HD18 HD19 TB17 TB18 TB19 TB20 TB21 TB22 Value Effect Full left Self-powered input point with external ground reference output point. Centered System-powered input point Full right Self-powered input point with ground reference at Termination Panel. A at 1--2 Cage address A (factory setting). B at 1--2 Cage address B. C at 1--2 Cage address C. D at 1--2 Cage address D. Both at “N” (1--2) Normal single FIM operation. Both at “R” (2--3) Redundant FIM operation Requires two FIMs and two communication lines. V--, SH and CH jumpered (4-tab jumper installed) Loop power negative and field wiring shields connected to chassis ground. Use with LPMs. (New factory setting.) SH to CH jumpered (4-tab jumper straddling TB18 or 2 tab jumper installed) Field wire shields connected to chassis ground. Use with locally grounded source of loop power. (Old factory setting with 2-tab jumper.) SH to CH open (Jumper removed) Allows connecting shield to a different ground reference than chassis. Jumpers fully installed, absent, or in “holder for loop position”. Fully installed: Power at TBA used for loop power. Holder position: Loop power connected at TB17. Absent: LPMs used for loop power. MAIO Termination Panel Fuses There are no fuses on the panel. Current limiting is provided by the FIM. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-29 MAI32 Termination Panel The MAI32 Termination panel is available in two versions. It is marked “MAI32 Termination Panel” on the PWA. The panel is CE approved. D D MAI32 4--20 mA Termination Panel with field terminals with field terminals and marshaling panel connector MAI32 Field Interface Module (FIM) 10P53490001 10P53490002 10P53190004 MAI32 is used to read up to 32 4--20 mA analog input points. The MAI32 termination panel can be remotely mounted within communication wiring length limits. Figure 6.4.14 shows the panel. The panel supports 32 analog input points using two termination panel addresses. The first address supports the Left Group of points (L1--L16), the second address supports the Right Group of points (R1--R16). An Analog Input Block (AIB) or a Smart Transmitter Input Block (SIB) must be configured for each address. Highway Addressable Remote Transducer (HART) variables can be addressed by configuring a Value Input Block (VIB). The Field I/O Status Screen (previously the FIC Status Screen) shows the type of device connected to each controller. The MAI32 FIM will have two entries, one for each cage address used. The type code is “MAI32--x” where the “x” shows the card cage of the OTHER set of 16 points. Thus if the panel is addressed as A and C, the first entry will show “MAI32--C” and the second will show “MAI32--A”. Wires can either be landed directly on the panel or at a remote location using multiconductor cables and remote marshaling panels. Terminal blocks TB1--TB4 are used to connect field wiring to the panel. All of the field wire shields are connected together within the panel. TB21 provides a way to connect all field wire shields to the panel chassis ground, tie them to an external ground, or leave them floating. Connectors J701 and J702 are used when a remote marshaling panel is desired. A combination of remote landing and local landing of field wires can be used. A source of loop power is required unless all points on the panel are self-powered inputs. Loop power is supplied by an external DC source (23 to 29 VDC) connected to TB23. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-30 15 16 14 17 17 13 12 18 11 19 10 20 21 22 9 20 8 23 7 20 6 24 5 25 20 4 26 3 20 2 1 Figure 6.4.14. MAI32 Analog Termination Panel RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-31 Table 6.4.6. MAI32 Analog Termination Panel Components Description No. No. Description 1 HD33: Panel (Card Cage) address jumpers. 14 Port B (J705): To daisy-chain the communication line to another panel. 2 HD34: Loop power detect jumpers. 15 Port C (J704): Not used. 3 HDL1--HDL8: Point Type jumpers for Left Points 1--8. 16 TBA Power Strip: For panel DC supply using stranded wire. Allows daisy chaining of DC power and access to panel chassis ground. 4 FL1--FL8: Fuses for Left Points 1--8. 17 Power Jack (J983): For panel DC supply using a 1984--0158--xxxx cable. 5 HDL8--HDL16: Point Type jumpers for Left Points 9--16. 18 TB23: External loop power terminal. 6 FL9--FL16: Fuses for Left Points 9--16. 19 TB21: Connects all field wiring shields to chassis ground when jumpered. 7 MAI32 Input FIM. 20 Shield Terminals (TB6--20): For field wiring shields. 8 HDR1--HDR8: Point Type jumpers for Right Points 1--8. 21 TB4: Field wiring terminals for Right Points 9--16. 9 FR1--FR8: Fuses for Right Points 1--8. 22 Marshaling panel connector (J702): Serves Left Points 1--16. 10 HDR8--HDR16: Point Type jumpers for Right Points 9--16. 23 TB3: Field wiring terminals for Right Points 1--8. 11 FR9--FR16: Fuses for Right Points 9--16. 24 TB2: Field wiring terminals for Left Points 9--16. 12 FIM LEDs. 25 Marshaling panel connector (J701): Serves Right Points 1--16. 13 Port A (J703): FIM Communication line. 26 TB1: Field wiring terminals for Left Points 1--8. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-32 MAI32 Termination Panel Installation See 6--1--1, “Multipoint I/O Installation and system Wiring” for installation, panel addressing, power wiring, and communication wiring, information. The MAI32 FIM requires one comm line connected to Port A. Port B can be used to daisy chain the comm line to another destination. Port C is not used. The MAI32 panel requires two Card Cage addresses that are set by jumper HD33. The alphabetically lowest jumper at 1--2 specifies the cage address for the Left Group of points (L1--L16). The next jumper at 1--2 specifies the address for the Right Group of points (R1--R16). The parity (P) jumper must be at 1--2 to establish the correct address parity. MAI32 Termination Panel Loop Power A source of loop power is required unless all points are self-powered inputs. The external source of loop power must be attached to TB23. The source must be in the range 23 to 29 VDC. The current draw will be under 700 mA. CAUTION Do not use the same source to power the panel and to supply loop power. This bypasses power isolation and can result in field wiring faults propagating to the power source. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-33 MAI32 Termination Panel Field Wiring Field wiring can be landed directly at terminal blocks on the panel. TB1 and TB2 serve the Left Group of points. TB3 and TB4 serve the Right Group. A Remote Marshaling Panel and cable can be used to land field wires at a remote location. Connector J701 serves the Left Group of points. Connector J702 serves the Right Group of points. Wiring can be mixed with some points landing directly on the panel and others landing at the remote marshaling panel. Field wiring is landed as shown in Figure 6.4.15. Field wire shields can be landed at the SHIELD terminals (TB6, 8, 10, 12, 14, 16, 18, 20). All field wire shields are connected together within the termination panel. Jumpering Terminal Block TB21 lets you connect all of the shields to the panel chassis ground. If TB21 is open, the shields are connected together but are floating relative to the panel ground. TB21 can also be used to connect the shields to an external ground. Figure 6.4.15. MAI32 Field Wiring NOTE: The negative (return) sides of all self-powered transmitters are connected to the negative (return) side of the Loop Power source. MAI32 Termination Panel labels Figure 6.4.16 shows the replaceable label (1984--4195--0011) that is provided on top of the termination panel label holder assembly. The label provides space at the end to record the ControlFile node address, the Controller slot address, the two termination panel (FIM) addresses, and the Communication Line number. The body of the label provides for recording each point’s field connection and the source of external loop power (V+, V--). The underside of the label shows examples of field wiring. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) L1 RS3: Multipoint I/O L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 R1 LOWER TP/CAGE ADDRESS SERVES POINTS ON THE LEFT SIDE OF THE TP R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 V+ UPPER TP/CAGE ADDRESS SERVES POINTS ON THE RIGHT SIDE OF THE TP V-- R COMM LINE L TP ADDR CNTRLR CP NODE SV: 6-4-34 Figure 6.4.16. MAI32 Field Wiring Label Multipoint Analog I/O (MAIO) SV: 6-4-35 MAI32 Termination Panel Jumpers All panel jumpers must be set to ensure correct operation as shown in Table 6.4.7. NOTE: Three jumpers are required for the ADDRESS (HD33). D D D The alphabetically lowest jumper at 1--2 specifies the cage address for the Left Group of points (L01--L16). The next jumper at 1--2 specifies the address for the Right Group of points (R01--R16). The third jumper (P) must be at 1--2 to establish correct address parity. Table 6.4.7. MAI32 Termination Panel Jumpers Jumper Position Effect HDL01--HDL16 HDR01--HDR16 Full left Point Type Full right HD33 One jumper A--C at 1--2 Cage address for Left Group of points L01--L16 (A is recommended) ADDRESS One jumper B--D at 1--2 Cage address for Right Group of points R01--R16 (B is recommended) System-powered input point Self-powered input point P at 1--2 Required for correct parity HD34 ENABLE Enables detection of loop power loss LOOP PWR DETECT DISABLE Disables detection of loop power loss TB21 SH and CH connected All field wiring shields are connected to panel chassis ground Shield Grounding SH and CH open All field wiring shields are connected together and are floating with respect to panel chassis ground SH connected to external ground All field wiring shields are connected together and are connected to the external ground point The Point Type jumpers (HDL1--HDL16, HDR1--HDR16) are set to define each point. Each jumper can be set fully to the left or fully to the right. A point can be defined as: RS3: Multipoint I/O D System-powered input Jumper fully left D Self-powered input Jumper fully right Multipoint Analog I/O (MAIO) SV: 6-4-36 System-Powered Input Point A system-powered input point requires a source of loop power at TB23. The Point Type jumper must be set fully to the left as shown in Figure 6.4.17. 1 2 LP + LP -- 3 4 + 5 -- 6 No. Description 1 System-powered input point 2 Input sense resistor 3 Point Type Jumper set fully to the left for system-powered input point 4 Fuse F1--F32 5 Field wiring terminal block: +, -- 6 System-Powered transmitter Figure 6.4.17. System-Powered Input Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-37 Self-Powered Input A self-powered input point requires no source of loop power. The return Point sides of all points are connected to the Loop Power return, The Point Type jumper must be set in the full right position as shown in Figure 6.4.18. 1 2 LP + LP -- 3 4 + 5 -- 6 No. Description 1 Self-powered input point 2 Input sense resistor 3 Point Type Jumper set fully to the right for self-powered input point 4 Fuse 5 Field wiring terminal block: +, -- 6 Self-powered transmitter Figure 6.4.18. Self-Powered Input Point RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-38 MAI32 Termination Panel Fuses Each input point is individually fused. Do not use a fuse larger than 1/10 amp 250V. Table 6.4.8. MAI32 Termination Panel Fuses Fuse FRSI Part No. Littlefuse Part No. Wickman Part No. Characteristics F1 to F32 G53394--0080--0005 Series 216 Series 19194 0.08 A 250V (IEC) Quick action 5x20 mm Ceramic RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-39 Loop Power Module (LPM) The Loop Power Module (LPM) (1984--4398--000x or 10P57070001) are marked “LOOP POWER MODULE” on the label. The LPM is used to supply power to the I/O loops. Figure 6.4.19 shows the LPM. Figure 6.4.19. Loop Power Module The LPM draws power from the termination panel where it is installed. It accepts redundant A and B supply voltages. Two LPMs can be used on a termination panel to provide redundant operation in which one will supply the loop power if the other fails. They operate in a “hot standby” mode and do not significantly share the load. The LPM produces up to 380 mA of DC current at 25.0 to 25.5 VDC. It is not adjustable. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-40 Figure 6.4.20 shows the LPM block diagram. 30 VDC Input Transformer and Power Switch EMI and Input Filter Switching Regulator Optical Isolator Rectifier and Filter 25 VDC Output Error Amplifier Figure 6.4.20. Loop Power Module Block Diagram The power supply consists of an EMI filter in the form of ferrite beads arranged in a pi configuration and an input filter for the normal mode switching currents on the power supply. This is followed by a transformer operating in the flyback mode of switching. The power switch is implemented by means of a Metal-Oxide Semiconductor (MOS) Field Effect Transistor (FET). The secondary rectifies the output during the relaxation phase of the flyback transformer to generate the output voltage. The feedback is by means of an error amplifier where the reference is generated by a 2.5V reference diode. The error amplifier is configured in a proportional plus integral mode of control that feeds an optical isolator in order to generate the correction feedback for the switching regulator. The switching regulator is a current mode switching regulator whose power is generated by means of zener diodes and transistors. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-41 Loop Power Module LEDs There are two LEDs on the LPM. Table 6.4.9 shows their meaning. Table 6.4.9. Loop Power Module LEDs LED GOOD (Green) BAD (Red) None Lit Meaning LPM functioning normally. LPM out of specification or failed. LPM out of specification, failed, or no input power. Loop Power Module Fuses There are no fuses in the Loop Power Module. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-42 MAIO FIMs Multipoint Analog FIMs are available for 16-point input or output and for 32-point input. There are three 16-point input FIMs: D D D MAIO16 Field Interface Module (FIM) CE Approved: 4--20 mA Input 16 Point 10P54040004 or 10P57700005 MAIO Field Interface Module (FIM): 4--20 mA Input 1984--4414--100x MAIO Field Interface Module (FIM) -- Nonredundant: 4--20 mA Input 1984--4414--0001 (FIM redundancy not supported) There are two 16-point output FIMs: D D MAIO16 Field Interface Module (FIM) CE Approved: 4--20 mA Output 16 Point 10P54080004 MAIO Field Interface Module (FIM): 4--20 mA Output 1984--4418--0001 There is one 32-point input FIM: D MAI32 Field Interface Module (FIM) CE Approved: 4--20 mA Input 32 Points 10P53190004 Table 6.4.10. MAIO FIM Parts Replacement Part Number Replaces 10P57700005 10P54040004 1984--4414--0001 Comments All cases 1984--4414--100x 1984--4414--100x 1984--4414--0001 All cases 10P54080004 1984--4418--000x All cases 10P53190004 -- RS3: Multipoint I/O No substitute exists Multipoint Analog I/O (MAIO) SV: 6-4-43 Analog FIM Redundancy Redundancy requires the use of two FIMs, two communications lines (two adjacent addresses, one odd and one even), and setting the jumpers at HD18 and HD19 on the Analog Termination Panel to the “R” position. The FIM at the odd numbered address is considered “primary”; the FIM at the even numbered address is “secondary”. If the primary FIM fails, the secondary FIM takes over. Normally the failed FIM red LED goes ON and the green LED flashes. The failed FIM should be removed and replaced with a good FIM. As soon as the new A FIM powers up, it takes over from the secondary FIM and resumes the duties of the primary FIM. If the secondary FIM fails, the primary FIM continues to operate. Normally the failed FIM red LED goes ON and the green LED flashes. The failed FIM should be removed and replaced with a good FIM. As soon as the good FIM powers up, it resumes the duties of the secondary FIM. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-44 16-Point Input FIMs The 16-point MAIO Input FIM is marked “4--20 mA ANALOG INPUT FIELD INTERFACE MODULE” on the label. There are two versions: D D MAIO16 Field Interface Module (FIM) CE Approved: 4--20 mA Input 16 Point 10P54040004 or 10P57700005 MAIO Field Interface Module (FIM): 4--20 mA Input 1984--4414--000x Both online replacement and full redundancy are supported by the FIM, depending on the termination panel in which it is installed. There are no field serviceable components in the FIM. The FIM case should not be opened. Figure 6.4.21 shows the MAIO input FIM. Figure 6.4.21. MAIO 16-Point Input FIM Figure 6.4.22 shows a simplified block diagram. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-45 Power Supply Block Inter FIM Communications Microprocessor Block Port A Port B Analog Input Block HART Dual Universal Asynchronous Receiver/Transmitter (DUART) Maintenance Port Analog Inputs 1--16 Figure 6.4.22. MAIO 16-Point Input FIM Block Diagram RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-46 16-Point Output FIMs The 16-point MAIO Output FIM is marked “4--20 mA ANALOG OUTPUT FIELD INTERFACE MODULE” on the label. There are two versions: D D MAIO16 Field Interface Module (FIM) CE Approved: 4--20 mA Output 16 Point 10P54080004 MAIO Field Interface Module (FIM): 4--20 mA Output 1984--4418--0001 Both online replacement and full redundancy are supported by the FIM, depending on the termination panel in which it is installed. There are no field serviceable components in the FIM. The FIM case should not be opened. Figure 6.4.23 shows the MAIO Output FIM. Figure 6.4.23. MAIO 16-Point Output FIM Figure 6.4.24 shows a simplified block diagram. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-47 Power Supply Block Inter FIM Communications Microprocessor Block Port A Port B Analog Output Block Readback Analog Outputs 1--16 HART Dual Universal Asynchronous Receiver/Transmitter (DUART) Maintenance Port Figure 6.4.24. MAIO 16-Point Output FIM Block Diagram RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-48 32-Point Input FIM The 32-point MAI Input FIM is marked “32-POINT 4 20 MA ANALOG FIELD INTERFACE MODULE” on the label. D MAI32 Field Interface Module (FIM) CE Approved: 4--20 mA Input 32 Points 10P53190004 The FIM supports 32 analog input points using two termination panel addresses. The first address supports the Left Group of points (L1--L16); the second address supports the Right Group of points (R1--R16). An Analog Input Block (AIB) or a Smart Transmitter Input Block (SIB) must be configured for each address. HART variables can be addressed by configuring a Value Input Block (VIB). The FIM and panel are keyed to prevent insertion of an incorrect FIM. The Field I/O Status Screen (previously the FIC Status Screen) shows the type of device connected to each controller. The MAI32 FIM will have two entries, one for each cage address used. The type code is “MAI32--x” where the “x” shows the card cage of the OTHER set of 16 points. Thus if the panel is addressed as A and C, the first entry will show “MAI32--C” and the second will show “MAI32--A”. Figure 6.4.25 shows the FIM. Figure 6.4.25. MAIO 32-Point Input FIM RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-49 MAIO FIM LEDs There are six LEDs on the MAIO FIM. Table 6.4.11 shows their meaning. Table 6.4.11. MAIO FIM LEDs Meaning LED RS3: Multipoint I/O On: FIM Good Flashing: FIM Inactive (Green) ON steady when the FIM is in normal operation. Flashing when the FIM is disconnected from the field. FIM Failure (Red) ON when FIM considers itself failed. Flashing when the FIM is not communicating with the Controller. Port A Active (Yellow) Flashes when communication Port A is active. Port B Active (Yellow) For factory use only. STATUS 1 (Yellow) Flashes steadily while the FIM operates. STATUS 2 (Yellow) Flashes a diagnostic code if the FIM is disabled and the red LED is ON. Multipoint Analog I/O (MAIO) SV: 6-4-50 MAIO FIM LED Patterns The 16-point MAIO FIMs can be operated as a single FIM (with online replacement capability) or as a fully redundant pair of FIMs. The 32-point input FIM can only operate as a single FIM. When the FIM boots up, the red LED goes ON, the green LED blinks briefly and then goes ON, the red LED goes off, and the yellow “Port A” LED begins to flash rapidly as the FIM communicates with the Controller Processor. The green LED blinks if there is no I/O block for any point configured in the Controller Processor or if the FIM is disconnected from the field due to redundancy operation, on-line replacement operation, or communication failure. Single FIM Operation Normal Operation: The green LED is ON and the yellow Port Active LEDs are flashing. The “Status 1” LED flashes regularly. If the FIM fails, the red LED goes ON, the green LED goes OFF, and the Port Active LEDs go out. Put a new FIM in the other socket. It should boot up with the green LED ON. Remove the failed FIM and return it for repair. Redundant FIM Operation Normal Operation: FIM A (primary) will have its green LED ON and FIM B (secondary) will have its green LED flashing. This is the normal operating condition. If the primary FIM (A) fails, its red LED should come ON. The green LED of the secondary FIM (B) should come ON as it assumes primary duty. Replace the failed FIM A. The replacement should boot up with the green LED ON as the new FIM resumes the primary duties. FIM B should then return to secondary function with the green LED flashing. If the secondary FIM (B) fails, its red LED will come ON. Replace the failed FIM B. The new FIM should boot up with the green LED flashing as it resumes the secondary function. RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-4-51 Failed FIM Indications A failed FIM will have the red LED ON. The yellow “Status 2” LED might flash a code number indicating the cause of the problem. The LED will flash a number of times, pause, and then flash the code again. Table 6.4.12 shows the meaning of the code. Code 5 shows a correctable problem; otherwise replace the FIM. NOTE: Please record the code and send it along when the FIM is returned for repair. A FIM with no LEDs lighted has an internal failure (or the DC supply has failed). If the DC supply is good, replace the FIM. The FIM’s Status 2 LED should never be continuously ON. The purpose, and the programming, for the LED is to blink a diagnostic code when a problem is detected. Table 6.4.12. MAIO FIM LED Patterns Meaning LED Code Number RS3: Multipoint I/O 1 RAM failure. 2 Voltage failure, one or more internal voltages are out of tolerance. 3 Point failure. 4 ADC failure. 5 Address jumpers on the termination panel are not set to A, B, C, or D. 6 Write or erase failure in FLASH. 7 Verification failure in BOOT or APP code. 8 Not assigned. 9 Not assigned. 10 Point diagnostic failure. 11 Temperature failure. Multipoint Analog I/O (MAIO) SV: 6-4-52 RS3: Multipoint I/O Multipoint Analog I/O (MAIO) SV: 6-5-1 Section 5: Multipoint I/O Marshaling Panel Many Multipoint I/O termination panels allow for remote landing of field wires on a remote marshaling panel. This version is available: D RS3: Multipoint I/O Standard Remote Termination Panel (1984--4344--000x) Multipoint I/O Marshaling Panel SV: 6-5-2 Standard Remote Termination Panel Figure 6.5.1 shows the Standard Remote Termination Panel (1984--4344--000x) used to connect field wiring to a Multipoint discrete termination panel. It is marked “STANDARD REMOTE TERMINATION PANEL” on the Printed Wiring Assembly (PWA). The panel may handle currents up to 1 amp per point. No fuses are supplied for the field wiring. Unshielded wire is used. J620 Connector to Termination Panel Label Holder 16+ (32+) 1+ (17+) Field Wiring Block, Positive Field Wiring Block, Negative 16-- (32--) 1-- (17--) Top View 1 2 1 3 2 4 3 5 4 6 5 7 6 8 9 7 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 Side View Figure 6.5.1. Standard Remote Termination Panel The panel snaps onto a standard DIN rail. The label holder provides a place to record the addresses of the points served by the panel. The panel is shipped with two sets of stick-on numbers so the the user may indicate the use of points 1--16 or 17--32. The Standard Remote Termination Panel can be connected to a discrete I/O termination panel with a Marshaling Panel Cable as shown in Table 6.5.1 RS3: Multipoint I/O Multipoint I/O Marshaling Panel SV: 6-5-3 Table 6.5.1. Standard Remote Termination Panel, Marshaling Panel Cable Application Use Cable Multi-FIM Termination Panel 1984--4299--xxxx Multi-FIM Termination Panel, Redundant FIMs 1984--4319--xxxx High Density Isolated Discrete Termination Panel 1984--4298--xxxx High Density Isolated Discrete Termination Panel, NEC/CSA 1984--4345--xxxx RS3: Multipoint I/O Multipoint I/O Marshaling Panel SV: 6-5-4 RS3: Multipoint I/O Multipoint I/O Marshaling Panel SV: 6-6-1 Section 6: Intrinsic Safety (IS) Operating electrical equipment in hazardous (classified) locations where flammable gases, flammable liquids, or other combustible materials exist requires special handling. One approach is to use equipment that is intrinsically safe, that is, equipment where the energy supplied to the hazardous area is not enough to ignite the materials present. RS3 System Normal Wires IS BARRIER Figure 6.6.1 shows this concept. The normal RS3 equipment is located in the Safe (nonhazardous) Area. The device being controlled is located in the Hazardous Area. An Intrinsically Safe Barrier (in the Safe Area) is used to isolate the Hazardous Area by limiting the energy that can be sent into the area. IS Wires Safe Area IS Device Hazardous Area Figure 6.6.1. Intrinsic Safety Example RS3 systems are designed for connection to IS products specified by Fisher-Rosemount Systems, Inc. (FRSI). RS3 supports IS applications with the Elcon IS Termination Panel and both MTL Discrete and Analog IS Termination Panels if proper installation practices are followed. Refer to RS3 Control Drawing for Intrinsically Safe Associated Apparatus and Field Wiring as Used in RS3 Equipment, 10P57190001, for complete recommendations and requirements. Standards for hazardous wiring practices include current versions of: D D Europe — EN50014, Electrical Apparatus for Potentially Explosive Atmospheres: General Requirements — EN50020, Electrical Apparatus for Potentially Explosive Atmospheres: Intrinsic Safety “I” Canada — RS3: Multipoint I/O C22.1, Canadian Electrical Code Part 1 Intrinsic Safety (IS) SV: 6-6-2 D United States — ANSI/ISA RP12.6, Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations — NFPA 70, National Electrical Code The rules and guidelines below apply to IS-associated RS3 equipment and in some nations or localities, may be required by law. Where local law or practices require deviation from these rules and guidelines, the deviations must be reviewed by FRSI prior to implementation. D D D D RS3: Multipoint I/O IS wiring and non-IS wiring cannot share the same cabinet cable entry locations. In addition, IS wiring must meet one or more of the following criteria: — Installed in a wireway separate from all non-IS wiring — Positively segregated from any non-IS wiring within an enclosure or cable tray by means of a grounded metal partition or an insulating partition in a wireway — Spaced at least 50 mm from any non-IS wiring and tied down. The non-IS wiring must also be secured to prevent it from violating the 50 mm spacing requirement. Care must be taken in terminal layout and wiring methods to prevent contact of IS and non-IS circuits. Some layouts will not provide adequate separation if a wire becomes disconnected (for example, when terminals are arranged one above the other). In these cases, additional precautions, such as tie-downs, are necessary. Wiring to an IS device must be installed following the instructions provided with each MTL or Elcon product. MTL provides instructions with their isolators. Elcon provides instructions with their discrete and analog termination panels and barriers/isolators. Wire routing requirements within RS3 equipment enclosures are provided in control drawing 10P57190001. This drawing is included with all shipments of the MTL IS Analog Termination Panels and MTL IS Discrete Termination Panels. Intrinsic Safety (IS) SV: 6-6-3 Elcon Series 1000 IS Termination Panel The Elcon Series 1000 Intrinsically Safe Termination Panel (Elcon P/N 1216/CW--ROS4) can be used for either discrete or analog applications. Figure 6.6.2 shows the panel and Table 6.6.1 describes its components. Dimensions are given as mm (inches). Up to 16 barriers can be installed to service up to 32 I/O points. Elcon provides a variety of galvanic isolation barriers to meet different requirements. The Elcon panel is used with an Multipoint Discret Input/Output (MDIO) termination panel which holds the RS3 Field Interface Module (FIM). NOTE: Elcon refers to their galvanic isolation barriers as “barriers”. The Elcon panel is characterized as analog or discrete at the factory by installing specific cross-wiring. A special tool (Elcon P/N 1301/PZ) is available to assist in changing the cross-wiring should a panel have to be converted in the field. Wire from 0.4 to 0.65 mm2 (26 to 22 AWG) can be used for cross wiring. Keying Plugs (Elcon P/N 601077) reduce the possibility of installing an incorrect barrier. Install keying plugs in all empty locations. This section describes: D Discrete applications D Analog applications D Common features of Elcon panels NOTE: See the Site Preparation and Installation Manual (SP: 7--5) for installation details and lists of available barriers. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-4 7 168 (6.6) (Module Inserted) 6 Side View 8 24 (0.9) 7 5 4 3 503 (19.8) Cross--Wiring Cover Top View 535 (21.1) 8 2 9 10 1 146 (5.8) 239 (9.4) 27 (1.1) Figure 6.6.2. Elcon Intrinsically Safe Termination Panel RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-5 Table 6.6.1. Elcon IS Termination Panel Components Description No. No. Description 1 DC power block 6 Cross-wiring cover 2 Fuse 7 Elcon Barrier 3 FIM cable connection C1 barriers 1--8 8 Hazardous area I/O terminals 4 FIM cable connection C2 barriers 9--16 9 Spare fuse 5 Cross-wiring block 10 Hazardous area shield ground RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-6 Elcon Panel for Discrete Applications Figure 6.6.3 shows how an Elcon panel is connected for discrete I/O applications and describes the components. Points 1--16 can be input or output, points 17--32 can only be inputs. 1 2 3 9 8 4 10 7 5 6 No. Description No. Description 1 ControlFile 6 Single FIM cable for points 1--16 (barriers 1--8) 2 Control cable 7 MDIO multi-FIM termination panel with one MDIO FIM 3 Communication Termination Panel II 8 Communication Line 4 Elcon IS Termination Panel with up to 16 barriers installed 9 MPC II or MPC5 controller 5 IS field wires 10 Single FIM cable for points 17--32 (barriers 9--16) Figure 6.6.3. Discrete I/O with Elcon IS Termination Panel RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-7 The MDIO Multi-FIM Termination Panel (1984--4282--000x) can support up to three Elcon panels. Each Elcon panel requires an MDIO FIM (1984--4080--000x) or MDIOL (10P53520006), a communication line, and two Single-FIM Cables (1984--4299--xxxx). FIM redundancy is available by use of the A and B FIMs as a redundant pair, two communication lines, two Redundant FIM Cables (1984--4319--xxxx), and proper jumpering. The C FIM can be used to support another Elcon panel or any other MDIO application. Elcon Panel Discrete Cross Wiring The Elcon panel is cross-wired at the factory. Figure 6.6.4 shows the cross-wiring for discrete applications. G H M N FROM T R V U J K TO G J H R M K N U Figure 6.6.4. Elcon Panel Cross Wiring for Discrete Applications RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-8 Elcon Discrete IS Barriers Table 6.6.2 shows the Elcon discrete barriers available for use with RS3. All of these discrete barriers are dual-channel so one barrier serves two consecutively numbered I/O points. The panel is polarized to prevent plugging in a module with current/voltage characteristics higher than the circuit design. Figure 6.6.5 shows module polarization. Open Hole Configuration 2 (26.4 V / 198 mA) Configuration 6 (26.4 V / 99 mA) Configuration 12 (Reverse Contact) Figure 6.6.5. Elcon Discrete Panel Polarization Table 6.6.2. Elcon Discrete IS Barriers Model Elcon P/N 1822 1822 C0 0030 CC 1842 Configuration Comment Contact/Proximitor Input, Relay Output 2 Input 1842 C0 0030 CC Contact/Proximitor Input, Optocoupler Output 2 Input 1862 1862 L0 0060 CC Contact Actuator 12 Output 1872 1872 L0 0060 WW Solenoid Valve Driver (35 mA per channel) 6 Output 1882 1882 L0 0060 UU Solenoid Valve Driver (70 mA per channel) Solenoid Valve Normally Energized 2 Output 1882 1882 L0 0060 WW Solenoid Valve Driver (70 mA per channel) Solenoid Valve Normally Deenergized 2 Output RS3: Multipoint I/O Description Intrinsic Safety (IS) SV: 6-6-9 Elcon Panel for Analog Applications Figure 6.6.6 shows how the Elcon panel is connected for analog applications. 1 2 3 11 10 4 5 9 6 8 7 Description No. No. Description 1 ControlFile 7 Point 1 2 Control cable 8 Marshaling panel cable 3 Communication Termination Panel II 9 MAIO Termination Panel with MAIO FIM 4 Elcon IS Termination Panel with 8 barriers installed 10 Communication line 5 Point 16 11 MPC II or MPC5 controller 6 IS field wires Figure 6.6.6. Analog I/O with Elcon IS Termination Panel RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-10 One MAIO Termination Panel (1984--4383--0002) and an MAIO FIM can support up to16 points on 8 dual-channel barriers. Use an MAIO Input FIM (10P54040004 or 10P57700005) for inputs or an MAIO Output FIM (10P54080004) for outputs. Use Marshaling Panel Cable 1984--4298--xxxx. Two MAIO Termination Panels are required to support all 16 barriers. One could be for inputs, the other for outputs. The FIM attached to Elcon panel connector C1 serves the first 16 points (barriers 1--8). The FIM attached to C2 serves the next 16 points (barriers 9--16). FIM redundancy on the MAIO panel requires use of two FIMs, two communication lines, but only one Marshaling Panel cable. Each barrier carries a wiring diagram showing how to terminate the field wiring. Loop Power and Jumpers An Elcon panel used for analog inputs requires no external source of loop power since the barrier supplies the power. A panel used for analog outputs requires a source of loop power, either from a Loop Power Module (LPM) on the MAIO Termination Panel or from an external DC source. Set all Point Type Jumpers (HD1--HD16) on the MAIO Termination Panel to the full left position. Elcon Panel Analog Cross Wiring The Elcon panel is cross-wired at the factory. Figure 6.6.7 shows the cross-wiring for analog applications. G H M N FROM T R V U J K TO G R H J M U N K Figure 6.6.7. Elcon Panel Cross Wiring for Analog Applications RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-11 Elcon Analog IS Barriers Table 6.6.3 shows the Elcon analog barriers available for use with RS3. All of these analog barriers are dual-channel so one barrier serves two consecutively numbered points. The panel is polarized to prevent plugging in a module with current/voltage characteristics higher than the circuit design. Figure 6.6.8 shows module polarization. NOTE: The type of FIM (input or output) determines the type of barrier used on the panel. Open Hole Configuration 6 (26.4 V / 99 mA) Configuration 7 (13.1 V / 26 mA) Figure 6.6.8. Elcon Analog Panel Polarization Table 6.6.3. Elcon Analog IS Barriers Model Elcon P/N 1012 1012 V0 0444 AA 1022 Configuration Comment Volt/mA Converter 7 Input 1022 A0 0242 AA Smart Transmitter Barrier (Low Frequency Protocols) 6 Input 1026 1026 A0 0242 AA Smart (High Frequency Protocols) or Non-Smart Transmitter Barrier 6 Input 1032 1032 H0 0242 AA Bus-Powered Analog Output Barrier 6 Output 1034 1034 H0 0242 AA Loop-Powered Analog Output Barrier 6 Output 1072 1072 D3 0510 AA RTD/tx Potential Converter 7 Output 1072 1072 F3 0510 AA RTD/tx Potential Converter 7 Output RS3: Multipoint I/O Description Intrinsic Safety (IS) SV: 6-6-12 Elcon Panel Common Features Elcon panels for analog or discrete applications differ in their cross-wiring and in the barriers installed. All other characteristics are common. DC Power Barriers on a panel can draw up to 3.2 amps in a discrete application and up to 1.92 amps in an analog application. The actual current draw depends on the number and type of barriers installed. CAUTION Elcon barriers require a DC source between 21.5 and 28 volts. Because the standard RS3 power bus can exceed these limits, do not power the panel directly from the standard DC bus. A Remote I/O Power Supply (1984--4302--0000x) can be used. Grounding The panel provides for two forms of grounding; one for the chassis and one for the hazardous-side field wire shields. The chassis ground screw must be connected to the local chassis ground. The hazardous-side shield grounding terminal must be connected to ground in accordance with local intrinsic safety grounding rules. Jumpers The jumpers on the Multi-FIM Discrete Termination Panel must be set as described in section 3 of this chapter. Fuses The panel has one fuse controlling power to the isolator barriers. There is a spare fuse in another fuse holder. Table 6.6.4 shows the fuse data. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-13 Table 6.6.4. Elcon IS Panel Fuses Panel FRSI P/N Wickman P/N Littelfuse P/N Characteristics Input G53394--1600--0005 19 194 1.60 A 216 1.60 1.6 Amp 5x20 mm Ceramic 250 V IEC Output G53394--3150--0005 19 194 3.15 A 216 3.15 3.15 Amp 5x20 mm Ceramic 250 V IEC Keying Keying Plugs (Elcon P/N 601077) must be inserted in the proper configuration for the module type to be installed. Empty locations must have all four keying plugs installed to prevent insertion of a module. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-14 MTL IS Termination Panel for Discrete Applications The MTL discrete IS panel is implemented as a set: D MDIO MTL IS Termination Panel A (10P5037000x) D MDIO MTL IS Termination Panel B (10P5049000x) The panels are marked “MDIO-MTLE I.S. ISOLATOR BARRIERS TERMINATION PANEL A” and “MDIO-MTLE I.S. ISOLATOR BARRIERS TERMINATION PANEL B” on the printed wiring assembly. Panel A holds 16 isolators that can serve up to 32 input points (1--32), up to 8 odd-numbered output points (1--15), or a combination of inputs and outputs. Panel B can hold 16 isolators but only 8 are used to serve the 8 even-numbered output points (2--16). Panel B is required only when there are more output points than can be served with Panel A or when FIM redundancy is required. NOTE: The MDIO FIM supports 16 input/output points (1--16) and 16 input-only points (17--32). The 8 odd-numbered output points (1--15) are mapped to Panel A, the 8 even-numbered points (2--16) are mapped to Panel B. NOTE: MTL refers to their galvanic isolator barriers as “isolators”. MTL provides a number of galvanic isolator barriers to meet different signal requirements. Hazardous-side field wiring is brought to a connector at the top of the isolator. NOTE: See the Site Preparation and Installation Manual (SP: 7--5) for installation details and Table 6.6.8 of this manual for a list of available barriers. Figure 6.6.9 shows Panel A (10P5037000x) and describes its components. Figure 6.6.10 shows Panel B (10P5049000x) and describes its components. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-15 7 6 8 9 10 5 11 4 12 3 13 2 14 1 15 16 Description No. No. Description 1 Isolator 16 -- Serves input points 31 and 32 9 Power Strip (TBD) for panel DC supply using stranded wire (Allows daisy chaining of DC power and access to panel chassis ground) 2 HD18 -- Common Line Fault Detect Jumper 10 Port B (TBB) -- Even-numbered communication line for redundant FIM B 3 Silk-screen label showing relationship of Isolators and I/O points 11 Port A (TBA) -- Odd-numbered communication line for FIM A 4 Isolator 1 -- Serves input points 1 and 2 or output point 1 12 HD1--HD16 -- Individual point Input/Output and Line Fault Detect selection jumpers 5 Fuse Blown LED 13 FIM A (required) 6 Fuse -- 3.15 Amp, 250 V, IEC 14 HD17 -- Panel (Card Cage) address (A, B, C, or D) 7 Power Jack (J636) for panel DC supply using a 1984--0158--xxxx cable 15 Mounting holes (2) for wire Tagging Kit 8 HD20--HD21 -- FIM redundancy jumpers 16 Connector (J635) for ribbon cable to Panel B Figure 6.6.9. MTL Discrete IS Termination Panel A RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-16 6 5 7 8 4 3 9 2 10 1 11 12 Description No. No. Description 1 Fuse Blown LED 7 HD17--HD32 -- Jumpers that enable/disable Common Line Fault Detect for the corresponding isolator 2 Fuse -- 3.15 Amp, 250 V, IEC 8 FIM B (optional) for redundancy 3 Isolator 24 -- Serves output point 16 9 Mounting holes (2) for wire Tagging Kit 4 Silk-screen label showing relationship of Isolators and I/O points 10 Power Jack (J982) for panel DC supply using a 1984--0158--xxxx cable 5 Isolator 17 -- Serves output point 2 11 HD1 -- Panel (Card Cage) address (A, B, C, or D) 6 Connector (J638) for ribbon cable to Panel A 12 Power Strip (TBD) for panel DC supply using stranded wire (Allows daisy chaining of DC power and access to panel chassis ground) Figure 6.6.10. MTL Discrete IS Termination Panel B RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-17 Figure 6.6.11 shows how the MDIO MTL IS Termination Panel is attached to an RS3 ControlFile. 1 2 3 4 5 6 8 7 9 10 Description No. 1 2 ControlFile with MPC II or MPC5 Controller Control Cable (1984--2783--xxxx non-EMC) (10P56510xxx EMC) No. Description 6 MTL Discrete IS Termination Panel A 7 IS field wiring (connects to top of isolators) 3 Communication Termination Panel II 8 Cable (1984--4186--9100) Panel A to Panel B 4 Communication Line (1984--4188--xxxx shielded twisted pair) connected to Port A of Panel A 9 MTL Discrete IS Termination Panel B 5 DC power for Panel A -- Connected to Power Jack or Power Strip 10 DC power for Panel B -- Connected to Power Jack or Power Strip Figure 6.6.11. Discrete I/O with MDIO MTL IS Termination Panel A and B FIM redundancy requires use of Panels A and B, two identical FIMs, two communication lines, and a Redundant I/O Block (RIOB). RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-18 Mapping I/O points to MTL Discrete Isolators Table 6.6.5 and Table 6.6.6 show the mapping of I/O points to isolators on the MTL discrete panels. Table 6.6.5. Mapping of I/O Points to MTL Discrete Panel A Isolators Isolator Position Input Point Output Point Isolator Position Input Point 1 1--2 1 9 17--18 2 3--4 3 10 19--20 3 5--6 5 11 21--22 4 7--8 7 12 23--24 5 9--10 9 13 25--26 6 11--12 11 14 27--28 7 13--14 13 15 29--30 8 15--16 15 16 31--32 Table 6.6.6. Mapping of I/O Points to MTL Discrete Panel B Isolators Isolator Position Output Point 17 2 18 4 19 6 20 8 21 10 22 12 23 14 24 16 25--32 RS3: Multipoint I/O Comment Isolator positions 17--24 serve even-numbered output points Positions 25--32 are currently not used Intrinsic Safety (IS) SV: 6-6-19 DC Power The MTL discrete isolators will function over the voltage range 20.7 to 36 VDC. The standard RS3 DC bus can range from 18 to 36 VDC. CAUTION The MTL discrete isolators can be operated from the standard RS3 DC bus but you must be aware that the isolators will stop operating at low voltage before the system stops. NOTE: Both discrete Panel A and Panel B require DC power connections. Grounding Grounding is accomplished by mounting the panel to a metal part that is grounded. When the panel is mounted on a nonconducting wall, a ground wire must be run to the ground terminal of the power strip. Communication Wiring A single communication line is connected to Port A for normal single-FIM operation. Two lines, connected to Port A and Port B, are required for redundant FIM operation. Field Wiring Hazardous-side field wiring is brought to a connector at the top of each MTL isolator. The hazardous-side wiring must follow local standards for intrinsic safety (refer to the first page of this section). Labels Descriptive labels on the discrete panels show the relationship between isolator positions and I/O points. Each panel has a place to record the address of the primary FIM. An optional label holder spans the length of the panel and provides a place to record the field wiring connection to each isolator. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-20 Fuses Each panel has a fuse and a “Fuse Blown” LED. The maximum allowed fuse size is 3.15 Amp, 250 Volt IEC. Table 6.6.7. MTL Discrete IS Termination Panel Fuses FRSI P/N Wickman P/N Littelfuse P/N Characteristics G53394--3150--0005 19 194 3.15 A 216 3.15 3.15 Amp 5x20 mm Ceramic 250 V IEC Line Fault Detection (LFD) Line Fault Detection (LFD) is available as an option on some isolators. Dual-channel inputs and all outputs can provide for the use of common LFD. Some single-channel inputs can provide individual-point LFD. The common LFD signal is returned on input point 32. NOTE: You can use a mixture of common and individual LFD. - To use common LFD: 1. Set the common LFD jumper (HD18 on Panel A) to “ENABLE”. This enables common LFD for both Panel A and Panel B. 2. For Panel A, set the appropriate jumper (HD1--HD16) for each isolator as shown on the panel label or in Figure 6.6.12 or Figure 6.6.13. 3. For Panel B, set the common LFD jumper for the isolator (HD17--HD32) to “ENABLE”. 4. Configure input point 32 to receive the common LFD signal. NOTE: The common LFD signal is delivered on input point 32. No isolator is required to receive this signal. When common LFD is used, you cannot install an isolator in position 16 of Panel A. - To use individual LFD: 1. Use a single-channel input isolator with LFD in any position of Panel A. 2. Set the appropriate jumper (HD1--HD16) as shown on the panel label or in Figure 6.6.12. 3. Configure the odd point as the control signal and the even point as the LFD signal. NOTE: Do not use LFD on MTL 4016. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-21 MTL Discrete Isolators Input isolators can be used only on Panel A. D Dual-channel input isolators connect to both the odd- and the even-numbered point served by the isolator position. Dual-channel isolators with LFD may use common LFD. NOTE: Do not use LFD on MTL 4016. D Single-channel input isolators connect to the odd-numbered point and supply the LFD signal on the even-numbered point. The corresponding even-numbered point on Panel B cannot be used. Output isolators can be used on either Panel A or Panel B. All output isolators are single channel. D D D Output isolators connect to the odd-numbered point when used on Panel A and to the even-numbered point when used on Panel B. Output isolators with LFD may use common LFD. You can use an output isolator on Panel A to serve the odd point and another output isolator on Panel B to serve the adjacent even point. NOTE: Isolator position 16 (Panel A) cannot be used when common LFD is enabled. Table 6.6.8 lists the MTL discrete isolators available for use with RS3. See the MTL product catalog for details. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-22 Table 6.6.8. MTL Discrete IS Isolators Input Isolators MTL P/N MTL4016 Name Switch/Proximity Detector Interface, With LFD Comment Dual-channel input -- Use PH-REV to have field agree with DCS. Do not use LFD. Output Isolators MTL4021 Solenoid/Alarm Driver Single-channel output -- Serves an odd-numbered point on Panel A or an even-numbered point on Panel B (has switch for phase direction) MTL4023 Solenoid/Alarm Driver, With LFD Single-channel output -- Serves an odd-numbered point on Panel A or an even-numbered point on Panel B (Common LFD is available) MTL4025 Solenoid/Alarm Driver, Low Current Output Single-channel output -- Serves an odd-numbered point on Panel A or an even-numbered point on Panel B RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-23 Panel A Jumpers FIM Address: Set FIM address jumpers (HD17) as for any other MIO panel. One jumper is set at 1--2 to select address A--D. The jumper at “F” must be at 1--2. FIM Redundancy: Set the FIM redundancy jumpers (HD20 and HD21) to “N” for normal single FIM operation or “R” for redundant FIM operation. Line Fault Detection: The common LFD jumper (HD18) must be set to “ENABLE” if any isolator on either panel uses common LFD. Otherwise, set it to “DISABLE”. NOTE: The common LFD signal is available on input point 32. An isolator serving point 32 is NOT required. Figure 6.6.12 shows the settings for the per-isolator jumpers (HD1 to HD16) when the point pair is used for input. HD1 TO HD16 JUMPER SETTINGS FOR INPUT(S) 1 2 3 4 1 2 3 4 1 2 3 4 I I I O O O INPUT(S) WITH INDIVIDUAL LFD INPUT(S) WITH COMMON LFD, ALSO ENABLE HD18 INPUT(S) WITH NO LFD Figure 6.6.12. LFD Jumper Settings for Input Points Figure 6.6.13 shows the settings for the per-isolator jumpers (HD1 to HD8) when the point pair is used for output. 1 2 3 HD1 TO HD8 JUMPER SETTINGS FOR OUTPUT(S) 4 1 2 3 4 1 2 OUTPUT(S) WITH COMMON LFD, ALSO ENABLE HD18 3 4 I I I O O O OUTPUT(S) WITH INDIVIDUAL LFD OUTPUT(S) WITH NO LFD Figure 6.6.13. LFD Jumper Settings for Output Points RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-24 Panel B Jumpers FIM Address: Set the Address jumpers (HD1) to the same address as used on Panel A. The jumper at “F” must be at 1--2. Line Fault Detection: The per-isolator common LFD jumpers (HD17 to HD24) are set to “ENABLE” if the isolator supports common LFD. All other jumpers are set to “DISABLE”. NOTE: The common LFD jumper (HD18) on Panel A must be set to “ENABLE” for per-isolator common LFD jumpers on Panel B to be effective. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-25 MTL IS Termination Panel for Analog Applications The MTL Analog IS Termination Panel (10P50340001) is shown in Figure 6.6.14. It is marked “MAIO-MTLE TERMINATION PANEL” on the printed wiring assembly. The panel holds 16 isolators and can handle either 16 input points or 16 output points depending on the FIM installed. Two FIMs are available: D MAI16 4--20 mA Input 10P54040004 or 10P57700005 D MAO16 4--20 mA Output 10P54080004 The MAI16 serves 16 input points; the MAO16 serves 16 output points. MTL provides a number of galvanic isolator barriers to meet different signal requirements. Hazardous-side field wiring is brought to a connector at the top of the isolator. NOTE: See the Site Preparation and Installation Manual (SP: 7--5) for installation details and Table 6.6.10 of this manual for a list of available barriers. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-26 7 8 6 9 5 10 4 3 2 11 1 No. Description 12 No. Description 1 HD3 Panel (Card Cage) address (A, B, C, or D) 7 Power Strip (TBD) for panel DC supply using stranded wire (Allows daisy chaining of DC power and access to panel chassis ground) 2 Socket for optional redundant FIM B 8 Fuse Blown LED 3 FIM A (required) 9 Fuse -- 3.15 Amp, 250 V, IEC 4 Port B (TBB) -- Even-numbered communication line for redundant FIM B 10 Isolator and point 16 5 Jumpers HD1--HD2 for FIM redundancy 11 Isolator and point 1 6 Port A (TBA) -- Odd-numbered communication line for FIM A 12 Address label -- Write the address of the primary FIM here An optional label holder spans the length of the panel and provides a place to record the field wiring connection to each isolator. Figure 6.6.14. MTL Analog IS Termination Panel RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-27 The MTL Analog IS Termination Panel is connected to an MPC II or MPC5 Controller in a ControlFile via a communication line as shown in Figure 6.6.15. 1 3 4 2 5 6 7 8 No. Description No. Description 1 ControlFile 5 Communication Line (shielded twisted pair) (two lines are required for FIM redundancy) 2 MPC II or MPC5 Controller in the ControlFile 6 DC power for MTL Analog IS Termination Panel 7 MTL Analog IS Termination Panel 8 IS field wiring (connects to top of isolators) 3 4 Control Cable (1984--2783--xxxx non-EMC) (10P56510xxx EMC) Communication Termination Panel II Figure 6.6.15. Analog I/O with MTL IS Termination Panel RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-28 DC Power The MAIO FIM allows loop power between the FIM and the isolator in the range 22 to 36 VDC. A Remote I/O Power Supply (1984--4302--0000x) can be used to supply 27 ¦ 1 VDC. The panel can use a redundant (A/B) DC supply. Grounding Grounding is accomplished by mounting the panel to a metal part that is grounded. When the panel is mounted on a nonconducting wall, a ground wire must be run to the ground terminal of the power strip. Communication Wiring A single FIM requires one communication line attached to Port A. Redundant FIMs require two communication lines: an odd-numbered line to Port A and the next even-numbered line to Port B. Use shielded twisted pair wires such as 1984--4188--xxxx. Field Wiring IS field wiring is landed at terminals on top of the isolators. Hazardous-side wire routing must follow local standards for intrinsic safety (refer to the first page of this section). Labels The panel has a place to record the address of the primary FIM. Fuses The panel has a fuse and a “Fuse Blown” LED. The maximum fuse size allowed is 3.15 Amp, 250 Volt IEC. Table 6.6.9. MTL Analog IS Termination Panel Fuses FRSI P/N Wickman P/N Littelfuse P/N Characteristics G53394--3150--005 19 194 3.15 A 216 3.15 3.15 Amp 5x20 mm Ceramic 250 V IEC RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-29 MTL Analog Isolators The MTL analog IS isolators that work with RS3 are listed below. See the MTL catalog for details. Table 6.6.10. MTL Analog Input and Output Isolators Input Isolators MTL P/N Description Comment MTL4041B Repeater Power supply, 4/20 mA, for 2- or 3-wire Transmitters (Smart Devices) Single-channel input -- Works with 2- or 3-wire 4/20 mA transmitters and smart transmitters MTL4041P High-power Repeater Power supply, 4/20 mA, for 2- or 3-wire Transmitters Single-channel input -- Works with 2- or 3-wire 4/20 mA transmitters and smart transmitters Output Isolators MTL4045B Isolating Driver, 4/20 mA, for I/P Converters Single-channel output -- Works with 4/20 mA current/pressure (I/P) converters MTL4046P High-power Isolating Driver, for HART Valve Positioners Single-channel output -- Works with 4/20 mA devices and HART valve positioners Jumpers FIM Address: The panel (Card Cage) address is set by jumper HD3. Only one jumper is allowed at the 1--2 position to specify the address as A, B, C, or D. FIM Redundancy: The redundancy jumpers (HD1--HD2) must be at “N” for single-FIM operation and at “R” for redundant FIM operation. RS3: Multipoint I/O Intrinsic Safety (IS) SV: 6-6-30 RS3: Multipoint I/O Intrinsic Safety (IS) RS3t Service Manual Chapter 7: PeerWay Interface Devices Section 1: System Resource Unit (SRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1 Section 2: Supervisory Computer Interface (SCI) . . . . . . . . . . . . . . . . . . . . . . 7-2-1 RS-232C Asynchronous Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . RS-422 Asynchronous Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 Asynchronous Protocol Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist for CE Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-422 X.25 Clocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EIA Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-3 7-2-6 7-2-8 7-2-9 7-2-11 7-2-12 7-2-13 7-2-14 7-2-15 Highway Interface Adapter (HIA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-1 HIA Direct Connection of PeerWays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIA Connection of PeerWays Using Modems . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for the HIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for HIA Direct Connection . . . . . . . . . . . . . . . . . . . . OI NV Memory Jumpering for HIA Connection Using Modems . . . . . . . . . . . . Checklist for CE Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure HIA Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIA Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-3 7-3-5 7-3-7 7-3-7 7-3-7 7-3-8 7-3-9 7-3-11 VAX/PeerWay Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-1 QBI Hardware Kit for the MicroVAX II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MicroVAX II -- PeerWay Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QBI Hardware Kit for the VAX 3xxx and VAX 4xxx . . . . . . . . . . . . . . . . . . . . . . . . . VAX 3xxx/VAX 4xxx -- PeerWay Marshaling Panel . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Marshaling Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Board 1 (CPU Card) Jumpers . . . . . . . . . . . . . . . . . . . VAX QBUS Interface Board 2 (PeerWay Interface Card) Jumpers . . . . . . . . . VAX QBUS Interface Board 2 (PeerWay Interface Card) LEDs . . . . . . . . . . 7-4-3 7-4-4 7-4-5 7-4-6 7-4-7 7-4-8 7-4-10 7-4-13 7-4-15 Section 3: Section 4: RS3: PeerWay Interface Devices Contents SV: ii Section 5: Section 6: Diogenes Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-1 OI NV Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Interface Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Interface TI Communications Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diogenes Communication Convertor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-4 7-5-5 7-5-6 7-5-7 RS3 Network Interface (RNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-1 RNI PeerWay Node Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI System Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boot Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crash Dumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI LEDs and Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RNI Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-3 7-6-4 7-6-6 7-6-6 7-6-6 7-6-7 7-6-8 7-6-9 7-6-10 RS3: PeerWay Interface Devices Contents SV: iii List of Figures Figure Page 7.1.1. SRU (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1 7.1.2. SRU (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-2 7.2.1. Supervisory Computer Interface (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-1 7.2.2. SCI Cabling Connections (Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-2 7.2.3. Possible SCI/Host Computer Communication Configurations: RS-232C Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-3 7.2.4. Standard RS-232C Cable Connector with SCI as a Terminal . . . . . . . . 7-2-5 7.2.5. Standard RS-232C Cable Connector with SCI as a Modem . . . . . . . . . 7-2-5 7.2.6. RS-422 Cable Connector: Asynchronous Protocol . . . . . . . . . . . . . . . . 7-2-8 7.2.7. RS-422 X.25 Protocol Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-9 7.2.8. RS-422 Cable Connector: X.25 Protocol . . . . . . . . . . . . . . . . . . . . . . . . 7-2-11 7.3.1. HIA (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-2 7.3.2. HIA Cabling (Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-3 7.3.3. PeerWays Connected by HIAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-4 7.3.4. HIA Modem Connection of PeerWays . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-5 7.3.5. Con HIA Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-9 7.3.6. HIA Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-11 7.4.1. VAX QBUS Interface Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-2 7.4.2. MicroVAX/PeerWay Interface Marshaling Panel . . . . . . . . . . . . . . . . . . . 7-4-4 7.4.3. VAX 3000 -- PeerWay Marshaling Panel . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-6 7.4.4. Circuit Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-9 7.4.5. Board 1 Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-10 7.4.6. Board 1 Memory Identification Jumper Positions . . . . . . . . . . . . . . . . . . 7-4-11 7.4.7. Board 1 I/O Space Code Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . 7-4-12 7.4.8. Board 2 Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-13 7.4.9. PeerWay Node Address Jumper Values . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-14 7.4.10. Board 2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-15 7.5.1. Diogenes Interface (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-2 7.5.2. Diogenes Interface (Back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-2 7.5.3. Diogenes/RS3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-3 7.5.4. Diogenes TI Comm Card Jumpering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-6 7.5.5. Diogenes Communication Converter Box Jumpering (Current Loop Connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5-7 RS3: PeerWay Interface Devices Contents SV: iv 7.6.1. RNI and Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-1 7.6.2. RNI Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-2 7.6.3. RNI label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-3 7.6.4. RNI System Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-4 7.6.5. RNI Fan and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-7 7.6.6. RNI Logic Board and Ethernet Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-9 7.6.7. RNI Fuse on Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-10 RS3: PeerWay Interface Devices Contents SV: v List of Tables Table Page 7.2.1. Definition of Some RS-232C Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-3 7.2.2. RS-232C Signals and Connector Pin Assignments . . . . . . . . . . . . . . . . 7-2-4 7.2.3. Definition of Some RS-422 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-6 7.2.4. RS-422 Pins and Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-7 7.2.5. X.25 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-10 7.2.6. CE Compliant Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-12 7.2.7. X.25 Clocking Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-13 7.2.8. EIA Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2-15 7.3.1. HIA/Black Box Cable Assembly Pin Assignments . . . . . . . . . . . . . . . . . 7-3-6 7.3.2. CE Compliant Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-8 7.3.3. HIA Status Screen Field Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-12 7.4.1. MicroVAX/Peerway Interface Marshalling Panel LEDs . . . . . . . . . . . . . 7-4-7 7.4.2. MicroVAX/PeerWay Interface Circuit Card Requirements . . . . . . . . . . 7-4-9 7.4.3. Board 1 Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-10 7.4.4. Board 2 LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4-15 7.6.1. RNI LEDs .................................................. 7-6-8 7.6.2. RNI Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-9 7.6.3. RNI Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-10 RS3: PeerWay Interface Devices Contents SV: vi RS3: PeerWay Interface Devices Contents SV: 7-1-1 Section 1: System Resource Unit (SRU) The System Resource Unit (SRU) provides additional computing power for control of batch processes and for trending. All components of the SRU are described in Chapter 3, Consoles. The SRU consists of these components: D OI Card Cage D OI Power Regulator D OI PeerWay Interface D OI Printer Interface D OI SCSI D OI Processor D Hard Disks (2) The Disk Shutdown (DS) command should always be performed before powering down the SRU. This will purge the cache and prevent possible loss of data. Figure 7.1.1 shows the front of the SRU. Figure 7.1.2 shows the connections on the rear side. Empty Power Regulator Slot PeerWay Interface Printer Interface SCSI Card OI Processor Hard Disk #1 Power Switch and Cable Hard Disk #2 Figure 7.1.1. SRU (Front) RS3: PeerWay Interface Devices System Resource Unit (SRU) SV: 7-1-2 PeerWay A 30 Volt Power Redundant 30 Volt Power (Optional) Connection for ON/OFF Switch 12 Volt Disk Drive Power Hard Disk Drive PeerWay B Fan Power (Red and Black Wires) Figure 7.1.2. SRU (Back) Hard disk #1 must have the SCSI address set to 5. Hard disk #2 must have SCSI address 6 and must have the three SCSI bus terminating resistors removed. RS3: PeerWay Interface Devices System Resource Unit (SRU) SV: 7-2-1 Section 2: Supervisory Computer Interface (SCI) The Supervisory Computer Interface (SCI) provides an interface between the RS3 and host computer systems. The SCI resides as a node on the PeerWay. The SCI may be connected to the supervisory computer by: D RS-232C Asynchronous Communication Protocol D RS-422 Asynchronous Communication Protocol D RS-422 X.25 Communication Protocol All components of the SCI are described in Chapter 3, “Consoles.” The SCI consists of: D OI Card Cage D OI Power Regulator D OI PeerWay Interface D OI NV Memory D OI Processor See the PeerWay Interface Manual (PW) for information on SCI configuration. Figure 7.2.1 shows the SCI and components. 3 2 4 1 No. Description 5 No. Description 1 Power Switch and Cable 4 OI Processor 2 OI Power Regulator 5 OI NV Memory Board 3 OI PeerWay Interface Figure 7.2.1. Supervisory Computer Interface (Front) RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-2 Figure 7.2.2 shows SCI connections. 1 2 3 4 5 6 No. Connector Cable Comments 1 J938 PWRB 1984--0158--1xxx (B Bus) (optional) DC power B (optional) 2 J937 PWRA 1984--0158--0xxx (A Bus) DC Bus to System Device (A Bus) 3 J936 POWER SWITCH 10P53110001 Power switch and cable 4 J084 PEERWAY A 1984--0473--0xxx PeerWay A Drop Cable 5 J083 PEERWAY B 1984--0473--0xxx PeerWay B Drop Cable 6 J939 FAN 1984--5311--0001 Cable, OI Card Cage to DC Fan Figure 7.2.2. SCI Cabling Connections (Rear View) RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-3 RS-232C Asynchronous Communications Protocol The RS-232C port is used to connect the SCI to the remote host computer when using RS-232C asynchronous protocol. The SCI may appear as either a terminal or a modem on the RS-232C port. An RS-232C cable (10P54340xxx) can be used to connect the SCI to the remote host computer. Figure 7.2.3 shows possible connections using the RS-232C port. SCI Port Appears as Terminal SCI Modem Modem Host SCI Port Appears as Modem SCI Host Host Port Appears as Terminal SCI Port Appears as Terminal SCI Host Host Port Appears as Modem Host Port Appears as Terminal Figure 7.2.3. Possible SCI/Host Computer Communication Configurations: RS-232C Port Table 7.2.1 defines some RS-232C terms. Table 7.2.1. Definition of Some RS-232C Terms RS3: PeerWay Interface Devices Signal Meaning TXD Data Transmit RXD Data Receive RTS Ready-To-Send CTS Clear-To-Send DSR Data Set Ready DCD Data Carrier Detect DTR Data Terminal Ready Supervisory Computer Interface (SCI) SV: 7-2-4 Table 7.2.2 shows the RS-232C connector pin assignments. Table 7.2.2. RS-232C Signals and Connector Pin Assignments Pin Signal Pin 1 ---- 14 2 TXD Data transmit 15 3 RXD Data receive 16 4 RTS Ready to send 17 5 CTS Clear to send 18 6 DSR Data set ready 19 ------------------- 7 Signal ground 20 DTR Data terminal ready 8 DCD Data carrier detect 21 9 10 11 12 13 ---------------- 22 23 24 25 Signal ------------------- NOTE: A standard PC printer cable can be used for the RS-232C cable. RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-5 Figure 7.2.4 shows the female plug to be connected to the SCI and indicates the pin functions when the SCI is to appear as a terminal. TXD -- Transmits Data to the Host RXD -- Receives Data from the Host RTS -- Tied to DTR in the SCI No connection DSR -- Pulled to +12 VDC Signal Ground CTS -- When asserted by the Host, SCI transmit is enabled. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DTR -- Asserted by the SCI when ready to talk to the Host. 21 22 23 24 Plug 25 Modem or Host Figure 7.2.4. Standard RS-232C Cable Connector with SCI as a Terminal Figure 7.2.5 shows the female plug to be connected to the SCI and indicates the pin functions when the SCI is jumpered to appear as a modem. RXD -- Receives Data from the Host TXD -- Sends Data to the Host No connection RTS -- Tied to DCD in the SCI DSR -- Asserted by the SCI when power is applied. +12 VDC Signal Ground DCD -- Asserted by the SCI when ready to talk to the Host. 1 2 3 4 5 6 14 15 16 17 18 19 20 CTS -- When asserted by the Host, SCI transmit is enabled. 21 22 23 Plug 24 Host 25 Figure 7.2.5. Standard RS-232C Cable Connector with SCI as a Modem RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-6 RS-422 Asynchronous Communications Protocol The RS-422 port on the SCI is used to connect the SCI to the supervisory computer when using either asynchronous or X.25 protocols. The SCI may be connected to the supervisory computer or modem by an RS-422 cable with a nonstandard connector on the SCI end (AMP HDC-20, P/N 205422--1 or equivalent). The SCI cannot be jumpered to look like a modem or terminal when using the RS-422 port. Cables from the RS-422 port to the host or modem must provide the electrical configuration. Table 7.2.3 gives a definition of some RS-422 terms. Table 7.2.3. Definition of Some RS-422 Terms RS3: PeerWay Interface Devices Signal Meaning TXD Data Transmit RXD Data Receive RTS Ready-To-Send CTS Clear-To-Send RXC Receive Data Clock TXC Transmit Data Clock Supervisory Computer Interface (SCI) SV: 7-2-7 Table 7.2.4 shows the RS-422 pin assignments. Table 7.2.4. RS-422 Pins and Signals Pin Signal Pin Signal 9 -- -- 2 -- --- -- 10 TXC+ (X.25 only) 3 CTS+ Clear to send 11 TXC-- (X.25 only) 4 CTS-- Clear to send 12 RXC+ (X.25 only) 5 RXD+ Data receive 13 RXC-- (X.25 only) 6 RXD-- Data receive 14 RTS+ Ready to send 7 TXD+ Data transmit 15 RTS-- Ready to send 8 TXD-- Data transmit 1 RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-8 RS-422 Asynchronous Protocol Cabling Figure 7.2.6 shows the male plug to be connected to the SCI and indicates the pin functions for RS-422 asynchronous protocol. Send data to Host Receive data from Host When asserted by the Host, SCI transmit is enabled. { { { TXD -TXD + RXD -RXD + 8 7 6 5 4 3 CTS -CTS + 2 1 15 14 13 12 RTS -RTS + } Asserted by the SCI when it is ready to talk to the Host. 11 10 9 Plug Host Figure 7.2.6. RS-422 Cable Connector: Asynchronous Protocol RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-9 RS-422 X.25 Protocol For the X.25 protocol, the SCI is configured both logically and electrically. The logical configuration of the SCI refers to its function in the exchange of data packets. Logically, the SCI can be the DCE or the DTE. The electrical configuration of the SCI refers to whether it functions as a modem or a terminal. Electrically, the SCI functions as a modem if it is directly connected to the host and as a terminal if it is connected to a modem. Figure 7.2.7 shows various RS-422 X.25 protocol connections. Modem Terminal SCI Host DCE (SCI is logically the DCE and electrically a modem) DTE Terminal SCI Terminal M M Host DTE DCE (SCI is logically the DCE and electrically a terminal) Terminal Terminal SCI M X.25 Network M Host DTE DTE (SCI is logically the DTE and electrically a terminal) Figure 7.2.7. RS-422 X.25 Protocol Connections RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-10 The X.25 parameters shown in Table 7.2.5 can be configured as directed by the installation instructions provided by the vendor of the host computer. Table 7.2.5. X.25 Parameters Parameter RS3: PeerWay Interface Devices Description K The maximum number of unacknowledged packets at both the link and network layers (1 to 7). T1 The link level transmission timeout (10 to 10,000 milliseconds). N1 The maximum network layer packet size (16 to 1024 bytes). N2 The maximum number of link level retries (1 to 100 attempts). T3 The link level idle transmit timeout (0 to 5000 seconds). If zero is selected, the link layer never times out. Supervisory Computer Interface (SCI) SV: 7-2-11 RS-422 X.25 Cabling For X.25 protocol, the cabling from the SCI to the modem or host determines whether the SCI is electrically configured as a modem or terminal. An SCI that implements X.25 protocol is shipped with a custom cable that electrically configures the SCI as a modem. In X.25 protocol, this cable connects the SCI directly to the host, as in Figure 7.2.8. The cable and RS-422 connectors carry the RS-422 electrical interface. If you want to configure the SCI electrically as a terminal, you must design a cable that performs that task. The clock jumpers on the OI NV Memory must be set for internal clocks if the SCI is configured as a modem or as external clocks if the SCI is configured as a terminal. Send data to Host Receive data from Host When asserted by the Host, SCI transmit is enabled. { { { TXD -TXD + RXD -RXD + RTS -8 7 6 5 4 3 CTS -CTS + 2 1 RTS + 15 14 13 12 11 10 9 RXC -RXC + TXC -TXC + } } } Asserted by the SCI when it is ready to talk to the Host. Clocks the data received. Clocks the Data transmitted. Plug Host Figure 7.2.8. RS-422 Cable Connector: X.25 Protocol RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-12 Checklist for CE Compliant Installation Follow these rules to ensure CE compliance: 1. Use cables specified in Table 7.2.6 as needed. 2. Install the card cage and mounting bracket in a grounded system cabinet. 3. Power the cage from a CE-approved power supply. 4. Use a CE-approved modem when a modem is required. Table 7.2.6. CE Compliant Cable Specifications Cable Part Number Maximum Length PeerWay Drop Cable 1984--0473--00xx 15.2 meters (50 feet) DC Power Cable, Bus To Product 1984--0158--0xxx 61 meters (200 feet) DC Power Cable, Power Supply to Product 1984--1083--00xx 15.2 meters (50 feet) Fan Power Cable 1984--1605--9009 Standard Cable, Highway Interface Adapter (HIA) to HIA 1984--2171--0004 1.2 meters (4 feet) Shielded RS-232 cable assembly, SCI to PC 10P54340xxx 15.2 meters (50 feet) Shielded RS-422 cable assembly, X.25/SCI 10P54390xxx 15.2 meters (50 feet) Shielded RS-422 cable assembly, HIA to Black BoxE 10P54400xxx 15.2 meters (50 feet) RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-13 RS-422 X.25 Clocking The clock lines of the RS-422 port (TXC and RXC) are for X.25 protocol only. TXC provides the transmit data clock signal and RXC the receive data clock signal. The direction of the clock lines is determined by the synchronous clock jumper settings on the NV Memory. If the SCI is electrically configured as a modem, the jumpers are set for the internal clock and the clock lines are driven by the SCI at the configured internal baud rate. In an SCI electrically configured as a terminal, jumpers are set for the external clock and clock lines supply clock signals to the SCI. A synchronous clock may be supplied internally at 300, 1200, 1800, 2400, 3600, 4800, 9600, 19.2K, 38.4K, and many higher rates. The SCI also accepts any external clock in the range 300 to 200K baud. At baud rates above 38.4K, multiple flags may be needed between packets to assure 500 microseconds between messages. NOTE: The NV Memory jumpers must match values entered on the SCI Configuration screen. Table 7.2.7 shows the X.25 clocking parameters. Table 7.2.7. X.25 Clocking Parameters Electrical Configuration of the SCI Nonvolatile Memory Jumper Configuration Source of Clock Signals Direction of Clock Lines (TXC and RXC) Modem Internal Clock SCI Output Terminal External Clock Modem Input RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-14 OI NV Memory Card The SCI uses the OI NV Memory which is described in Chapter 3, “Consoles.” Jumpers on the OI NV Memory must be set to match the communications protocol in use. See the description of the appropriate OI NV Memory card in Chapter 3 for jumper setting information. RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-15 EIA Options The EIA options are selected on the SCI Configuration screen for asynchronous protocol using the RS-232C or RS-422 ports. The present implementation of X.25 protocol does not provide EIA options. The EIA options available are: CTS, MODEM, and NONE. The CTS option is a hardware means of flow control. Flow control can also be enabled in software by selecting XON and XOFF control on the SCI Configuration screen. When the host sends XOFF, the SCI stops sending messages until it sees XON. XON and XOFF control is not implemented for X.25. The EIA options are described in Table 7.2.8. Table 7.2.8. EIA Options Description EIA Option CTS SCI configured as a modem: When DTR (pin 20) is asserted by the host, the SCI can transmit. SCI configured as a terminal: When DCD (pin 8) is asserted by the host, the SCI can transmit. SCI configured as a terminal: The SCI monitors the modem Carrier Detect (CD) signal to determine when the host has called in. When DTR (pin 20) is asserted by the SCI, the modem answers the phone and establishes the carrier. When DTR is dropped by the SCI, the modem hangs up the line. Unless dropped to hang up the line, this pin remains asserted once software initialization is complete. MODEM DCD (pin 8) is asserted by the modem to inform the SCI that the data carrier is detected. NONE No EIA option is selected. RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-2-16 RS3: PeerWay Interface Devices Supervisory Computer Interface (SCI) SV: 7-3-1 Section 3: Highway Interface Adapter (HIA) The Highway Interface Adapter (HIA) connects two PeerWays. It resides as a node on one PeerWay and communicates with another HIA that is a node on the other PeerWay. The HIA pair is connected to provide PeerWay-to-PeerWay communications: D Directly, for adjacent PeerWays D By modem, for geographically separated PeerWays All HIA components are described in Chapter 3, Consoles. The HIA consists of: D OI Card Cage D OI Power Regulator D OI PeerWay Interface D OI NV Memory D OI Processor Figure 7.3.1 shows the HIA and its components. See the PeerWay Interfaces Manual (PW) for information on the configuration of HIA software. RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-2 4 3 5 2 6 1 No. Description No. Description 1 Power Regulator 4 OI NV Memory Board 2 Power Switch and Cable 5 PeerWay Interface 3 Empty Slot 6 OI Processor Figure 7.3.1. HIA (Front) RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-3 HIA Direct Connection of PeerWays Two HIAs that providing a direct PeerWay-to-PeerWay connection are typically contained in a shelf assembly side-by-side with an HIA Link Cable (1984--2171--00xx) joining the RS-422 connectors. Figure 7.3.2 shows the rear view of two directly connected HIAs. 1 2 3 7 4 5 6 No. Connector 1 J938 PWRB 1984--0158--1xxx (Bus B) (optional) DC power B (optional) 2 J937 PWRA 1984--0158--0xxx (Bus A) DC Bus to System Device (Bus A) 3 J936 POWER SWITCH 10P53110001 Power switch and cable 4 J084 PEERWAY A 1984--0473--0xxx PeerWay A Drop Cable 5 J083 PEERWAY B 1984--0473--0xxx PeerWay B Drop Cable 6 J939 FAN 1984--5311--0001 Cable, OI Card Cage to DC Fan 7 RS-422 (J086) to RS-422 (J086) 1984--2171--0004 The cable is 1.2 meters (4 feet) long. Cable Comments Figure 7.3.2. HIA Cabling (Rear View) RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-4 FRSI recommends that PeerWays connected by HIAs be configured to provide alternate communication paths in the event of communication failure. For example, Figure 7.3.3 shows four PeerWays connected by HIAs. Dual HIAs may be used as shown at the right side of the figure. If communications fail between a pair of HIAs, data can still be routed to the proper destination. HIA HIA HIA HIA HIA HIA HIA HIA HIA HIA PeerWay 1 PeerWay 3 PeerWay 2 PeerWay 4 Figure 7.3.3. PeerWays Connected by HIAs RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-5 HIA Connection of PeerWays Using Modems Distant PeerWays may be connected by the use of HIAs, Converters, Modems, and a communication line as shown in Figure 7.3.4. This is referred to as HIA Modem. Each HIA modem group consists of: D HIA D Black BoxÒ Data Converter (Customer furnished) D HIA/Black Box Cable Assembly D Synchronous Modem (Customer furnished) The Data Converter used is a Black Box IC454--187 (or equivalent), which converts between RS-422 and RS-232 formats. Set the Data Converter to modem operation on the HIA side and to terminal operation on the modem side. 2 3 4 5 1 No. Item 1 Cable 10P54400xxx from RS-422 (J086) to Black BoxE 2 Black BoxE Data Converter 3 RS-232C data cable 4 Modem 5 Communications line Comments The cable length (xxx) is in decimeters. Maximum is 15.2 meters (50 feet) Model IC454--187 (or equivalent) Must be a shielded cable Must be CE approved Runs to a matching set connected to the other PeerWay Figure 7.3.4. HIA Modem Connection of PeerWays RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-6 An HIA/Black Box Cable Assembly (1984--2859--00xx) is required between the HIA and the Data Converter. The cable connects the 15-pin RS-422 connector on the HIA to the 37-pin RS-449 connector on the Data Converter. Table 7.3.1 shows the cable pin assignments. The modems must be set to agree with the rest of the equipment. The OI NV Memory card jumpers and the Configure HIA screen must be set to agree with the particular connections used. Table 7.3.1. HIA/Black Box Cable Assembly Pin Assignments Twisted Pair Signal Wire Color RS-422 Connector (HIA) RS-449 Connector (Black Box) 1 RXD -RXD + Black Red 6 5 6 24 2 RTS -RTS + Black White 15 14 7 25 3 TXC -TXC + Black Green 11 10 5 23 4 RXC -RXC + Black Blue 13 12 8 26 5 TXD -TXD + Black Yellow 8 7 4 22 6 CTS -CTS + Black Brown 4 3 9 27 1--6 Drain Wires Ground Drain Wires 2 19, 20, 37 Jumper Wire White (.25 mm2 24 AWG) 7 TO 12 Jumper Wire White (.25 mm2 24 AWG) 25 TO 30 RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-7 OI NV Memory Jumpering for the HIA The RS-422 Terminal/Modem jumpers on the OI NV Memory Card determine the source of the HIA clock synchronization. For jumper locations and settings see the OI NV Memory card description in Chapter 3, Section 6: “OI Card Cage.” CAUTION The Configure HIA screen of each HIA must agree with the jumper settings on that HIA. OI NV Memory Jumpering for HIA Direct Connection One HIA in the pair must be jumpered as a modem (internal clocking). The other HIA must be jumpered as a terminal (external clocking). The HIA jumpered as a modem (internal clocking) is the source of the clock synchronization signal. The Configure HIA screen must agree with the jumper setting for each HIA. OI NV Memory Jumpering for HIA Connection Using Modems Each HIA must be jumpered as a terminal (external clocking). RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-8 Checklist for CE Compliant Installation Follow these rules to ensure CE compliance: 1. Use cables specified in Table 7.3.2 as needed. 2. Install the card cage and mounting bracket in a grounded system cabinet. 3. Power the cage from a CE approved power supply. 4. Use a CE approved modem when a modem is required. Table 7.3.2. CE Compliant Cable Specifications Cable Part Number Maximum Length PeerWay Drop Cable 1984--0473--00xx 15.2 meters (50 feet) DC Power Cable, Bus To Product 1984--0158--0xxx 61 meters (200 feet) DC Power Cable, Power Supply to Product 1984--1083--00xx 15.2 meters (50 feet) Fan Power Cable 1984--1605--9009 Standard Cable, HIA to HIA 1984--2171--0004 1.2 meters (4 feet) Shielded RS-232 cable assembly, SCI to PC 10P54340xxx 15.2 meters (50 feet) Shielded RS-422 cable assembly, X.25/SCI 10P54390xxx 15.2 meters (50 feet) Shielded RS-422 cable assembly, HIA to Black BoxE 10P54400xxx 15.2 meters (50 feet) RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-9 Configure HIA Screen An HIA is configured with the Configure HIA screen, which displays the information necessary for HIA operation, as shown in Figure 7.3.5. Each HIA must be configured on the PeerWay to which it is connected. CONFIGURE HIA 21- mar-94 Node number >10 (10 on PeerWay 1) Other node PeerWay number 1 Other PeerWay 2 11:47:12 64 (32 on PeerWay 2) Node 10 Configuration Information Program version xx.xx Boot version x.xx Distance penalty 24 Baud rate 614400 Clock src CLK_INT Link passing time 1.0 s Slot width 30 Time correction .00 sec/day Pass time yes Volume,Filename for Program xxx,xxxx Volume,Filename for Config xxx,xxxx operation Save HIA configuration to config file %Press <ENTER> to Begin CONFIG 1 Figure 7.3.5. Configure HIA Screen The “Baud rate” field entry must match the baud rate used. For direct connection this is 614400 baud. The modem connection baud rate is determined by the modems or the converters used. The “Clock src” field entry on the Configure HIA screen must match the clock jumper position for each HIA used. Only “CLK_EXT” and “CLK_INT” are allowed. Pressing [PAGE AHEAD] from the Configure HIA screen calls up the HIA Status screen. The HIA Status screen contains communications diagnostic information. RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-10 See the PeerWay Interfaces Manual (PW) for a complete description of this screen and for more information on HIA configuration. An HIA pair can support up to 40 links over the HIA connection. The number of available links can be viewed on the PeerWay Node screen for the HIA. NOTE: The Configure HIA screen of each HIA must agree with the jumper settings on that HIA. RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-11 HIA Status Screen Pressing [EXCHANGE] from the Configure HIA screen calls up the HIA Status screen. The HIA Status screen contains communications diagnostic information as shown in Figure 7.3.6. The data shows 4-second averages for the two connected HIAs. Table 7.3.3 gives definitions of the fields. HIA Status Display 14- Mar-94 09:20:50 Node number >28 (28 on PeerWay 1) Other node 62 (62 on PeerWay 2) Program vers 11.22 Program vers 11.22 Boot vers 8.72 Boot vers 8.72 NRoute 168 CRC 0 NRoute 185 CRC 0 RCount 206 Size 0 RCount 206 Size 0 XCount 204 BCount 0 XCount 206 BCount 0 ICount 410 LRC Overrun 0 0 ICount 409 LRC Overrun 0 0 RTic 16 XToss 0 RTic 16 XToss 0 RLink RDist 16 0 RToss 0 RLink RDist 16 0 RToss 0 RNode 0 TimeOut 0 RNode 0 TimeOut 0 RPoint RAck 91 127 TicLost LnkLost 0 0 RPoint RAck 99 123 TicLost LnkLost 0 0 RStat 83 RNack 0 RStat 73 RNack 0 MaxHop 0 RBusy REng 0 0 MaxHop 0 RBusy REng 0 0 DupRoute 4 BadSeq 0 DupRout 7 BadSeg 0 NoPath ReQueue 0 0 XBusy XEng 0 0 NoPath ReQueue 0 0 XBusy XEng 0 0 CONFIG 2 Figure 7.3.6. HIA Status Screen RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-3-12 Table 7.3.3. HIA Status Screen Field Definitions Definition Item NRoute Point-to-point messages routed across this HIA. RCount Messages received directly from the partner HIA. XCount Messages transmitted. ICount Level 3 direct communication interrupts. RTic TIC messages received directly from the partner HIA. RDist Distance information messages received. RNode Node/type information messages received. RPoint Point-to-point messages received. RAck ACK direct messages received (piggybacked on HIA partner message). RStat Partner HIA direct communication status messages received. MaxHop Messages discarded for taking more than the maximum number of hops. DupRout Duplicate route messages (a message ID with the same, or higher, content has been seen). NoPath ReQueue Messages in which this HIA does not know the current path to the destination node. Messages requeued for transmission on another path. CRC Messages with bad Cyclical Redundancy Check received from partner HIA. Abort Direct messages aborted. Size Number of messages received with size errors. BCount Number of messages received with byte count errors. Overrun Number of messages received with overrun errors. (scaled x1) Number of messages received with gross transmit communications timeouts. (scaled x200) 403 means 2 transmit timeouts and 3 overrun errors. XToss Transmit messages toss for debugging. RToss Received messages toss for debugging. TimeOut Transmit queue timeouts. TicLost TIC messages lost (unacknowledged). LnkLost LINK messages lost (unacknowledged). RNack Not acknowledged responses received from the partner HIA. RBusy Buffer busy responses received. REnq Status enquiries received from partner HIA. BadSeq Bad message sequence number ID for messages between HIAs. XBusy Busy responses sent to partner HIA (HIA direct buffers busy). XEnq Status enquiries sent to partner HIA. RS3: PeerWay Interface Devices Highway Interface Adapter (HIA) SV: 7-4-1 Section 4: VAX/PeerWay Interface The VAX QBUS Interface provides a link between an RS3 and a Digital VAXÒ computer system. The VAX QBUS Interface resides as a node on the PeerWay and connects to the VAX QBUSÒ. There are two QBUS to PeerWay Interface (QBI) kits for different types of VAX. D D QBI Hardware Kit, MicroVAX II Series (1984--2530--0001) QBI Hardware Kit, MicroVAX 3xxx and VAX 4xxx Series (1984--2627--0001) The VAX 3xxx/4xxx kit works with systems with BA213 or BA215 cabinets such as the 3300, 3400, 35xx, 36xx, 3800, 3900, and the VAX 4000. The kits share the PeerWay Interface board and one short cable. They differ in the marshaling panel and the long cable. Figure 7.4.1 shows the VAX QBUS Interface installed in a MicroVAX II cabinet. RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-2 VAX Cabinet VAX QBUS Marshaling Panel PeerWay Drop Cables Special PeerWay A Cable Special PeerWay B Cable Figure 7.4.1. VAX QBUS Interface Installation RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-3 QBI Hardware Kit for the MicroVAX II The kit for the MicroVAX II consists of: D D D D D D MicroVAX II -- PeerWay Marshaling Panel (MicroVAX II) (1984--2533--0001) marked “QBI” on the front panel QBUS Board 1 (CPU Card) (1984--3261--0002 or 1984--2507--0002) QBUS Board 2 (PeerWay Interface Card) (1984--2510--0001) Cable, QBUS Board #1 to Board #2 (2” long) (1984--2504--9002) Cable, QBUS Boards to MP (1984--2535--9901) PeerWay Drop Cables, MicroVAX (1984--2628--1006 and 1984--2628--2006) RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-4 MicroVAX II -- PeerWay Marshaling Panel The MicroVAX/PeerWay Interface Marshaling Panel (1984--2533--000x) is shown in Figure 7.4.2. One end of the QBus Board to the MP-MicroVAX II cable (1984--2535--9901) is connected to the connector located behind the Marshaling Panel, as shown in the side view of Figure 7.4.2. The Marshaling Panel is installed in a blank panel on the back of the MicroVAX. The special PeerWay Drop cables (1984--2628--1006 and 1984--2628--2006) are connected to the front of the Marshaling Panel. FAULT B1 TXA RXA Ä Ä TXB A Front View FAULT B2 RXB ............ Ä Ä B .. . . . . . . . . . . . Side View Connector Red ribbon of cable should be at this end of the connector. Figure 7.4.2. MicroVAX/PeerWay Interface Marshaling Panel RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-5 QBI Hardware Kit for the VAX 3xxx and VAX 4xxx The kit for the MicroVAX 3xxx or VAX 4xxx consists of: D D D D D D D MicroVAX II -- PeerWay Marshaling Panel (MicroVAX 3000) marked “RPQNA” on the front panel (1984--2622--0001) Cover Plate, DEC (1984--2642--0001) QBUS Board 1 (CPU Card) (1984--3261--0001) QBUS Board 2 (PeerWay Interface Card) (1984--2510--0001) Cable, QBUS Board #1 to Board #2 (2” long) (1984--2504--9002) Cable, QBUS Boards to MP (1984--2535--9901) PeerWay Drop Cables, MicroVAX (1984--2628--1006 and 1984--2628--2006) RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-6 VAX 3xxx/VAX 4xxx -- PeerWay Marshaling Panel The MicroVAX/PeerWay Interface Marshaling Panel (1984--2622--0001) and Cover Plate (1984--2624--0001) are shown in Figure 7.4.3. One end of the QBus Board to MP-MicroVAX II cable (1984--2625--9901) is connected to the connector located behind the Marshaling Panel. The Marshalling Panel is installed in the cover plate and then in the back of the MicroVAX. The special PeerWay Drop cables (1984--2628--1006 and 1984--2626--2006) are connected to the front of the Marshaling Panel. FAULT B2 B1 TXA RXA TXB RXB A B RPQNA Figure 7.4.3. VAX 3000 -- PeerWay Marshaling Panel RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-7 VAX QBUS Interface Marshaling Panel LEDs LEDs show activity of the interface and indicate board faults. Figure 7.4.2 and Figure 7.4.3 show the LEDs. Table 7.4.1 gives the meanings of the LEDs. If B1 or B2 is ON, the corresponding card is bad. B1 and B2 will alternate ON and OFF after the Interface is powered up but not yet booted. Both B1 and B2 will be ON while the diagnostics are running. If they stay ON, both cards may be bad. Table 7.4.1. MicroVAX/Peerway Interface Marshalling Panel LEDs LED Description B1 (RED) Indicates the condition of the CPU card (board 1). B2 (RED) Indicates the condition of the PeerWay Interface card (board 2). TXA (YELLOW) Indicates transmission of data to PeerWay A. Blinks when data is sent. TXB (YELLOW) Indicates transmission of data to PeerWay B. Blinks when data is sent. RXA (YELLOW) Indicates reception of data from PeerWay A. Blinks when data is received. RXB (YELLOW) Indicates reception of data from PeerWay B. Blinks when data is received. RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-8 VAX QBUS Interface Circuit Cards The VAX QBUS Interface contains two circuit cards: D D QBUS Board 1 (CPU card) 1984--3261--0002 marked “QBUS TO PEERWAY INTERFACE I+” or 1984--2507--000x marked “QBUS TO PEERWAY INTERFACE I” QBUS Board 2 (PeerWay Interface) (1984--2510--000x) marked “QBUS TO PEERWAY INTERFACE II” The circuit cards must be located in the VAX QBUS after the CPU and memory cards and before any disk and tape controller cards. Two complete quad slots must be reserved for the VAX QBUS Interface circuit cards. No gaps can exist between cards in the VAX. If, by moving the disk and tape controller cards or some other cards, a dual slot gap exists, a Digital Equipment Corporation Grant Continuity Card (model M907) must be put into the empty dual slot. Figure 7.4.4 shows proper installation. Board 1 should be in the right quad slot. Board 2 should be in the left quad slot. The long cable that is attached to the Marshaling Panel must be connected to the bottom connector of Board 2. The short cable (1984--2504--9002) must be connected from Board 1 to Board 2. The VAX must also be able to supply enough power to the circuit cards. The requirements for each card are listed in Table 7.4.2. NOTE: Be certain that the circuit boards are properly seated in the VAX. Improper seating may result in hard to trace operating problems. RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-9 Board 2 1984--2510--000x Board 1 1984--3261--000x or 1984--2507--000x VAX CPU Short Cable 1984--2504--9002 Long Cable Cabinet Adaptor Red ribbon of cable Figure 7.4.4. Circuit Card Installation Table 7.4.2. MicroVAX/PeerWay Interface Circuit Card Requirements Item Board 1 (CPU Card) 1984--3261--000x 1984--2507--000x Board 2 (PeerWay Interface Card) 1984--2510--000x 5 VDC current 4A 1.5 A 12 VDC current ------ 700 mA Total Watts 20 W 15.9 W AC bus loads 1 AC load 0 AC load DC bus loads 1 DC load 0 DC load RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-10 VAX QBUS Interface Board 1 (CPU Card) Jumpers Board 1 contains the VAX QBUS Interface memory identification jumpers and the DEC I/O space code jumpers. Figure 7.4.5 shows the locations of these jumpers, Table 7.4.3 shows settings. HD2 Memory Identification Jumpers HD1 HD13--HD18 I/O Space Code Jumpers HD4--HD8 Figure 7.4.5. Board 1 Jumper Locations Table 7.4.3. Board 1 Jumper Settings Jumper Setting HD1 2--3 (1984--2507--000x board only) Factory setting, do not move. HD2 2--3 Factory setting, do not move. HD4--HD8 See text for data I/O Space Code, determines the base address used. HD13--HD18 See text for data Memory Identification, first or second memory window. HD29--HD30 RS3: PeerWay Interface Devices Function Not used. VAX/PeerWay Interface SV: 7-4-11 Memory Identification Jumpers: A VAX can hold up to two VAX QBUS Interfaces. Each VAX QBUS Interface is assigned a memory window by the memory identification jumpers. There are two valid jumper positions, as shown in Figure 7.4.6. It does not matter which jumper position is used. However, note the jumper position for entry into the VAX. 1 2 3 HD18 HD18 HD17 HD17 HD16 HD16 HD15 HD15 HD14 HD14 HD13 HD13 4 Jumper position to use the first memory window. 1 2 3 4 Jumper position to use the second memory window. Figure 7.4.6. Board 1 Memory Identification Jumper Positions RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-12 I/O space code jumpers: The I/O space code jumpers determine the base address used by the VAX QBUS Interface. The jumpers are originally set for a base address of 766020 octal. If the VAX QBUS Interface needs to have a base address other than 766020 octal, these jumpers must be positioned for the correct base address. Figure 7.4.7 describes the I/O space code jumper settings. Base address 7 6 6 0 2 0 This digit is determined by jumpers HD4 and HD5. HD5 is the most significant digit. This digit is determined by jumpers HD6, HD7, and HD8. HD6 is the least significant digit and HD8 is the most significant digit. The 3--4 jumper position represents a 0 value. Never use the 1--2 jumper position. The 2--3 jumper position represents a 1 value. 1 2 3 4 HD4 HD5 HD4 HD5 HD6 HD6 HD7 HD7 HD8 HD8 1 2 3 4 1 This is the jumper position of the shipped board and represents 766020 octal. 2 3 4 This jumper position represents 766540 octal. HD4 is in the 0 value position and HD5 is in the 1 value position; they represent a value of 4 octal. HD6 and HD8 are in the 1 value position and HD7 is in the 0 value position; they represent a value of 5 octal. Figure 7.4.7. Board 1 I/O Space Code Jumper Positions RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-13 VAX QBUS Interface Board 2 (PeerWay Interface Card) Jumpers Board 2 (PeerWay Interface) contains the PeerWay node address jumpers. These jumpers are positioned to provide the PeerWay address of this node. Figure 7.4.8 shows the location of these jumpers. Figure 7.4.9 shows how to position these jumpers to indicate the PeerWay node address. Node address jumpers Figure 7.4.8. Board 2 Jumper Locations RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-14 Sum of jumper values +1 node address Pin J1 J2 J3 J4 J5 1--2 1 2 4 8 16 2--3 0 0 0 0 0 Node Address = 15 J1 J3 J5 Sum of jumper values 0 + 2 + 4 + 8 + 0+ 1 = 15 1 2 3 J2 J4 Node Address = 29 Sum of jumper values 0 + 0 + 4 + 8 + 16 + 1 = 29 J1 J3 J5 1 2 3 J2 J4 Figure 7.4.9. PeerWay Node Address Jumper Values RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-4-15 VAX QBUS Interface Board 2 (PeerWay Interface Card) LEDs Board 2 (PeerWay Interface) has LED indicators, as shown in Figure 7.4.10 and described in Table 7.4.4. (Yellow) Communication to VAX (Yellow) Communication from VAX (Yellow) Static data update (Yellow) Dynamic data update (Yellow) Data scan (Red) Fuse (Red) Fuse (Red) Diagnostics (Green) Figure 7.4.10. Board 2 LED Indicators Table 7.4.4. Board 2 LEDS Mode LED Indications Power on, but not yet booted; board reset The bottom two LEDs alternate on and off and the bottom yellow LED is ON. Diagnostics The bottom red LED is ON. The yellow LEDs blink as diagnostics run. Running RS3: PeerWay Interface Devices The green LED is ON. The yellow LEDs blink as indicated above. VAX/PeerWay Interface SV: 7-4-16 RS3: PeerWay Interface Devices VAX/PeerWay Interface SV: 7-5-1 Section 5: Diogenes Interface The Diogenes Interface provides a connection between an RS3 and a Rosemount Diogenesâ control system. The RS3 Diogenes Interface resides as a node on the PeerWay and connects to the Diogenes via a TI Comm Card. The Diogenes Interface consists of: D Operator Interface (OI) Card Cage D OI Power Regulator D OI PeerWay Interface D OI NV Memory D OI Processor Card D Diogenes TI Communications Card (7900--408--0001) D Diogenes Communications Connection Box (Optional) D Diogenes Cables The Console Card Cage, OI PeerWay Buffer, OI Power Regulator, OI Processor, and OI NV Memory Card are described in Chapter 3, “Consoles.” The remaining equipment is described in this section. Figure 7.5.1 shows the Diogenes Interface and its components. Figure 7.5.2 shows the connections on the Console Card Cage motherboard. RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-2 Empty Slot OI PeerWay Interface OI NV Memory Board Empty Slot OI Processor OI Power Regulator Power Switch and Cable Figure 7.5.1. Diogenes Interface (Front) PeerWay A 30 Volt Power Redundant 30 Volt Power (A Bus) (Optional B Bus) Connection for ON/OFF Switch RS-232C Cable to Diogenes PeerWay B Fan Power (Red and Black Wires) Figure 7.5.2. Diogenes Interface (Back) RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-3 Figure 7.5.3 shows two methods of connecting the systems. Diogenes RS3 Direct RS-232 connection TI Comm Card Max 50 Feet Cable 7900--0355--0005, --0006, --0007, or --0008 Diogenes Diogenes Interface RS3 Current loop RS-232 connection TI Comm Card Max 1 KM Cable 7900--0166--000x Communication Converter Box Max 50 Feet Cable 7900--0164--000x Diogenes Interface Figure 7.5.3. Diogenes/RS3 Connections RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-4 OI NV Memory Card The OI NV Memory card must have the terminal/modem jumpers in the terminal position. See Chapter 3, Consoles, for the location and setting of the jumpers. RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-5 Diogenes Interface Software Diogenes Interface Software must be loaded into the OI Processor card and the PeerWay Interface NV Memory card. RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-6 Diogenes Interface TI Communications Card The Diogenes Interface requires a TI Communications card (7900--0408--0001) in one of the Diogenes TI 960B Communications Register Unit Card Cage Console or SCI interface slots. Refer to the Diogenes User’s Manual for information about installing TI Comm Cards in the TI 960B. Figure 7.5.4 shows the TI Comm Card jumper positions for a RS-232 connection and for a current loop connection. TI Comm Card (7900--408--0001) jumpering for RS-232 connection TI Comm Card (7900--408--0001) jumpering for current loop connection Figure 7.5.4. Diogenes TI Comm Card Jumpering RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-7 Diogenes Communication Convertor Box The Diogenes Communication Converter Box is only used for the current loop connection. It must be properly jumpered for a Diogenes/RS3 current loop connection. To access the jumpers, unplug the Communication Converter Box, remove the four cover screws, and take off the cover. Figure 7.5.5 shows the required jumper positions. TERMINAL/MODEM T M CONTROL Y N POWER SUPPLY CAUTION HIGH VOLTAGE Figure 7.5.5. Diogenes Communication Converter Box Jumpering (Current Loop Connection) RS3: PeerWay Interface Devices Diogenes Interface SV: 7-5-8 RS3: PeerWay Interface Devices Diogenes Interface SV: 7-6-1 Section 6: RS3 Network Interface (RNI) The RS3t Network Interface (RNI) (10P53330001) provides a connection between the PeerWay and an Ethernet Local Area Network. It is a node on the PeerWay and a host on the Ethernet. Software in the RNI provides a connection between PeerWay messages and Ethernet messages. Figure 7.6.1 shows the RNI in the rack-mounting bracket. See the RNI Programmer’s Reference Manual (RP) for application programming data and the RNI Release Notes and Installation Guide (RI) for software installation. Figure 7.6.1. RNI and Mounting Bracket RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-2 PW A/B ERROR ETHERNET 10 BASE T HW GOOD PEERWAY B PEERWAY A HW BAD 1 2 No. 3 Item CONSOLE / RESET SERIAL 1 SWITCH ETHERNET 10 BASE 2 4 5 COMM 6 18 -- 36 VDC INPUT POWER TMSTR 7 8 No. 9 Item 1 Ethernet 10BaseT connector 6 LEDs 2 PeerWay B drop cable 7 Console/Serial connector for terminal communicating with the RNI 3 PeerWay A drop cable 8 Reset switch 4 Write-on label 9 DC power connector 5 Ethernet 10Base2 connector Figure 7.6.2. RNI Front View RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-3 RNI PeerWay Node Label The PeerWay node number, PeerWay number, and Ethernet name used for the RNI should be written on the label (1984--4438--000x) on the front of the RNI. The factory fills in the MAC Address of the CPU board. Figure 7.6.3 shows the label. PEERWAY NODE E-NET HOST MAC ADDRESS E-NET 10 BASE T NUMBER E-NET 10 BASE 2 Figure 7.6.3. RNI label RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-4 RNI System Cabling The RNI connects to both an RS3 PeerWay and to an Ethernet Local Area Network as shown in Figure 7.6.4. 2 1 A B 4 3 5 7 6 8 8 No. Item No. Item 1 PeerWays A and B 5 DC power cable 2 PeerWay Tap Boxes A and B 6 10BaseT or 10Base2 Ethernet connector 3 PeerWay Drop Cables A and B 7 Ethernet 4 RNI 8 Computers on Ethernet Figure 7.6.4. RNI System Cabling DC Power Use a 1984--0158--00xx cable for bus A power, or a 1984--0158--20xx cable for A/B power. Use a 10-amp fuse in the DC Distribution Card. There is no power switch on the RNI. PeerWay The RNI is connected to the PeerWay by a set of standard PeerWay Drop Cables (1984--0473--xxxx). CAUTION The RNI cannot supply adequate current to power an Optical Tap Box or a PeerWay Extender (PX). It can power a twinax Tap Box. RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-5 Ethernet The RNI connects to the Ethernet by a 10baseT twisted pair or 10Base2 coaxial cable. Use of other Ethernet media requires an external converter. NOTE: The RNI is normally shipped jumpered for use with 10BaseT twisted pair wiring. Serial Port Cable A cable (10P55180007) is supplied to connect your ASCII terminal to the Console/Serial connector. The cable has a RJ-11 connector on each end. Two adaptors are provided: a RJ-11 to 9-pin Dsub (10P55130001) and a RJ-11 to 25-pin Dsub (10P55130002). The adaptor fastens to the serial port of your PC and then allows the cable to connect to the RNI. This cable is used in the startup procedure and for servicing the RNI. Label Write the PeerWay Node Number and the Ethernet device name on the label. RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-6 Serial Port The serial port, identified as “CONSOLE/SERIAL1” on the front panel, provides a way to interact with the internal operating system of the RNI. You can attach any kind of ASCII terminal to the port using the supplied cable. Use a terminal emulator program in your PC to communicate with the RNI over the serial port. Set it for RS-232 communication using 9600 Baud, 8 bits, no parity, and no handshaking. The dialogs are described in the RNI Release Notes and Installation Guide (RI). Boot Data You can see the boot data through the serial port. This is often useful in diagnosing configuration problems. Crash Dumps The latest crash dump is available over the serial port. Press the Reset button to initiate the daialog and request the dump. RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-7 RNI Fan The RNI Fan assembly (10P53910001) plugs into jack J4 on the RNI power supply board. The fan runs on DC provided by the power supply board. The fan is the only field-replaceable component of the RNI. Fan Logic Board J4 Power Supply Board Figure 7.6.5. RNI Fan and Connections RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-8 RNI LEDs and Reset Switch There are six LEDs on the RNI as described in Table 7.6.1. NOTE: When the red/green pair of LEDs flash alternately, there is a message on the serial port. Table 7.6.1. RNI LEDs LED Color Meaning HW GOOD Green The hardware has passed all diagnostic tests and is running normally. HW BAD Red The hardware has failed one or more diagnostic tests. The RNI is not operating. COMM Yellow Blinks when internal communications occur in normal operation. PW A/B Yellow ON when PeerWay A is active. OFF when PeerWay B is active. Indicates failure of a diagnostic test if the red LED is ON and this LED flashes. The number of flashes indicates the failed test. ERROR Yellow TMSTR Yellow Reset Switch 1 2 3 4 5 6 7 8 9 10 11 12 CPU ROM CRC Memory Controller Main Memory 68302 Static Memory Main Memory Size TRAP Exceptions TEA Exceptions Read/Write Latch Real Time Clock Watchdog Interrupt Ethernet Loopback ON if the RNI is the PeerWay Tick-Master. Pressing the Reset Switch causes the RNI to reboot and run the startup diagnostics. You can observe the process by connecting a terminal to the serial port. RS3: PeerWay Interface Devices RS3 Network Interface (RNI) SV: 7-6-9 RNI Jumper Internal jumper HD1 selects Ethernet format as either 10BaseT or 10Base2. The default type is 10BaseT. The selected Ethernet type is marked on the label. You can change to 10Base2 by opening the case and moving the jumper. Be sure to change the marking on the label. Figure 7.6.6. RNI Logic Board and Ethernet Jumper Table 7.6.2. RNI Jumper Jumper Position HD1 10BASE2 The 10Base2 Ethernet connector is enabled. ETHERNET 10BASET The 10BaseT Ethernet connector is enabled. RS3: PeerWay Interface Devices Effect RS3 Network Interface (RNI) SV: 7-6-10 RNI Fuse There is one fuse on the power supply board. Figure 7.6.7 shows the location of the fuse. F1 POWER SUPPLY BOARD Figure 7.6.7. RNI Fuse on Power Supply Board Table 7.6.3. RNI Fuse Fuse FRSI Part Numer Littelfuse Part Numer Schurter Part Numer Characteristics F1 G50382--0021 273003 MSF 034.4224 2 Amp Plug-in RS3: PeerWay Interface Devices RS3 Network Interface (RNI) RS3t Service Manual Chapter 8: Calibration Section 1: Section 2: Section 3: Section 4: Section 5: RS3: Calibration Calibrating Serial I/O Field Interface Cards . . . . . . . . . . . . . . . . . 8-1-1 Serial I/O Analog Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Serial I/O Analog Output Points . . . . . . . . . . . . . . . . Calibrating Serial I/O Analog Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . Calibrating Serial I/O Analog Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-2 8-1-3 8-1-4 8-1-5 8-1-6 8-1-7 Calibrating Temperature Input FICs . . . . . . . . . . . . . . . . . . . . . . . . 8-2-1 Temperature Input FIC Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple Sensor Calibration Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple Sensor Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2-2 8-2-6 8-2-7 Calibrating Pulse Input FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3-1 Pulse Input FICs Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3-2 Calibrating MUX FEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-1 Entering Calibration Constants for Multiplexer FEMs . . . . . . . . . . . . . . . . . . . . . . . Calibrating Voltage Input and Thermocouple FEMs . . . . . . . . . . . . . . . . . . . . . . . Checking and Calibrating Voltage Input and Thermocouple FEMs . . . . . . . . . Calibrating 4--20 mA FEMs ........................................... Checking and Calibrating the 4--20 mA FEM . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of RTD FEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking RTD FEM Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-2 8-4-3 8-4-5 8-4-7 8-4-8 8-4-9 8-4-10 Calibrating Analog I/O Field Interface Cards .............. 8-5-1 Analog I/O Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Analog I/O Output Points . . . . . . . . . . . . . . . . . . . . . . Calibrating Non-Isolated Analog I/O Output Points .................... Calibrating Isolated Output FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration of Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . Calibrating Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Analog I/O Input Points Setup Using Current Input . . . . . . . . . Calibrating Analog I/O Input Points Setup Using Voltage Input . . . . . . . . . Calibrating Analog I/O Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-3 8-5-4 8-5-6 8-5-7 8-5-8 8-5-9 8-5-10 8-5-10 8-5-11 8-5-12 Contents SV: ii Section 6: RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6-1 Checking and Calibrating MAIO Output Points . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Calibrating MAIO Input Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6-1 8-6-4 Contents SV: iii List of Figures Figure RS3: Calibration Page 8.1.1. I/O Block Configuration Screen (AOB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-2 8.1.2. Connecting a Meter for Output Calibration . . . . . . . . . . . . . . . . . . . . . . . 8-1-3 8.1.3. I/O Block Configuration Screen (AIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-5 8.1.4. Connecting a Meter for Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-6 8.2.1. Calibrating a Millivolt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2-2 8.3.1. Pulse Input Field Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3-1 8.4.1. Voltage and Thermocouple FEM Calibration . . . . . . . . . . . . . . . . . . . . . . 8-4-3 8.4.2. 4--20 mA FEM Calibration for 1984--0607--0004 . . . . . . . . . . . . . . . . . . . 8-4-7 8.4.3. RTD FEM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-9 8.5.1. AOB Block Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-3 8.5.2. FIC Calibration Setup for Current Output . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-5 8.5.3. I/O Block Configuration Screen (AIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-8 8.5.4. Current Input FIC Calibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-10 8.5.5. Voltage Input FIC Calibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-11 8.6.1. Rosemount 262 Field Calibrator Connection for Output Calibration . . 8-6-1 8.6.2. Analog Output Block (AOB) Configuration Screen . . . . . . . . . . . . . . . . . 8-6-2 8.6.4. Rosemount 262 Field Calibrator Connections for Input Calibration . . . 8-6-4 Contents SV: iv List of Tables Table RS3: Calibration Page 8.1.1. Serial I/O Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-1 8.2.1. Calibration Resistance for Ohm Sensor Types . . . . . . . . . . . . . . . . . . . . 8-2-1 8.2.2. Calibration Voltage for Millivolt Sensor Types . . . . . . . . . . . . . . . . . . . . . 8-2-1 8.4.1. Multiplexer Front End Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4-1 8.5.1. Analog I/O Field Interface Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5-1 Contents SV: 8-1-1 Section 1: Calibrating Serial I/O Field Interface Cards This section covers calibration of the serial I/O Field Interface Cards (FIC) listed in Table 8.1.1. Serial I/O FICs are housed in Analog Card Cages and are connected to Multipurpose Controller Processors (MPC) in the ControlFile. CAUTION The calibration procedures in this section apply only to the FICs listed in Table 8.1.1. Table 8.1.1. Serial I/O Field Interface Cards Characteristics FIC 1984--2480--000x Two input/one output (4--20 mA) FIC, no redundancy 10P54440002 or 1984--2518--000x Two input/one output Three input (4--20 mA) FIC, standard (4--20 mA) FIC, standard 10P54440002 or 1984--2519--000x Two input/one output (4--20 mA) FIC, with Smart Transmitter Interface Serial I/O FICs perform all Analog to Digital (A/D) conversions on the FIC itself. All communications between the FIC and the Controller Processor Card are by serial digital data stream. The calibration correction constants for each serial analog input point and analog output point are stored on the serial I/O Field Interface Card. With all constants and correction factors stored on the card, the Field Interface Card can be removed, calibrated at a remote location, and then moved back to the original location with full accuracy. NOTE: Field Interface Cards are calibrated at the factory; therefore calibration in the field should not be necessary. However, to ensure accuracy, calibration should be checked at 6-month intervals. Recalibration is not required when a Controller Processor Card is replaced. Calibration is done through the operator console I/O BLOCK CONFIGURATION screens by using a Rosemount 262 Field Calibrator. Alternatively, a calibrated current source may be used for the inputs and a high quality multimeter with a milliampere function may be used for the outputs. NOTE: All calibration and checking procedures require the use of a Configuror’s key. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-2 Serial I/O Analog Output Points The procedure for checking and calibrating serial I/O analog output points is given below. An output point includes the FIC and the Analog Output Block (AOB). Calibration constants are stored on the FIC. Figure 8.1.1 shows the I/O BLOCK CONFIGURATION screen used in the calibration procedures. Address =1AA103 Block Tag Þ I/O BLOCK CONFIGURATION Device Type AOB 25-Jan-90 Block Type ÞAOB Mode ®MANUAL Auto Lock Þno Source Tag Þ Value .00 Eng Units Reverse Acting 10:42:34 Actual Value -.00 Output Value >.00 .00% Þno Calibrate 0% Value. 100% Value Alarm Priority Þ0 Plant Unit Þ0 Hardware Alarm Code 0 Fail Safe Jumper Hold Output Card Rev 2.1 ®None 4. ma 20. ma CONFIG 1 Figure 8.1.1. I/O Block Configuration Screen (AOB) WARNING The following calibration procedures require that the process measurement or output drive be completely disconnected from the control system. Any control scheme using a measurement to be calibrated must be in MANUAL mode. Any devices connected to an output to be calibrated must be isolated from the process. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-3 Checking Calibration of Serial I/O Analog Output Points - To check the calibration of serial I/O analog output points: 1. If there is I/O redundancy, remove the redundant Field Interface Card (FIC) from service. 2. Disconnect the FIC output field wiring at the marshaling panel and replace it with a Rosemount 262 Field Calibrator (set up as an ammeter). The connection depends on whether the output point is jumpered for self power or for system power. a. For a self powered output point, connect the calibrator as shown in Figure 8.1.2 and select button 3 on the calibrator. b. For a system powered output point, reverse the leads shown in Figure 8.1.2 and select button 1 on the calibrator. 101 A 103 102 B A B A B Rosemount 262 Figure 8.1.2. Connecting a Meter for Output Calibration 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 4. Enter 0 (or the Engineering minimum) in the “Output Value” field of the I/O Block Configuration screen. 5. The meter reading must be 4.000±.016 mA. 6. Enter 100 (or the Engineering maximum) in the “Output Value” field of the I/O Block Configuration screen. 7. The meter reading must be 20.000±.016 mA. Recalibrate the analog output point if the values read on the meter are not within the specified range. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-4 Calibrating Serial I/O Analog Output Points NOTE: Before calibrating any point, carefully check the accuracy of the calibration device. - To calibrate a serial I/O analog output point: 1. If there is I/O redundancy, remove the redundant Field Interface Card (FIC) from service. 2. Disconnect the FIC output field wiring at the marshaling panel and replace it with a Rosemount 262 Field Calibrator (set up as an ammeter). The connection depends on whether the output point is jumpered for self power or for system power. a. For a self powered output point, connect the calibrator as shown in Figure 8.1.2 and select button 3 on the calibrator. b. For a system powered output point, reverse the leads shown in Figure 8.1.2 and select button 1 on the calibrator. 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. Cursor to the “Calibrate” field. Use [NEXT OPTION] to get “Cal Low” in the “Calibrate” field. Press [ENTER]. The cursor will jump to the “0% Value” field. 4. Enter the current value read from the Rosemount 262 Field Calibrator in the “0% Value” field. Press [ENTER]. The “Calibrate” field will change to “Cal High”. 5. Cursor to the “100% Value” field. Enter the current value read from from the Rosemount 262 Field Calibrator in the “100% Value” field. Press [ENTER]. 6. The system will begin the Calibrate function. The “Calibrate” field will change to “Calibrate”. The FIC will generate exactly 4.00 mA and then exactly 20.00 mA. The internal calibration correction factors for the feedback resistor will be calculated and permanently stored in the internal memory of the Controller Processor Card. Wait for the “Calibrate” field to change to “None”. CAUTION Do not disconnect the meter from the circuit until the word “None” appears in the “Calibrate” field. If the meter is disconnected too early, the calibration sequence will not be completed and improper calibration constants will be entered into the Controller’s internal memory. 7. Reconnect the field wiring and return the AOB to AUTO. NOTE: Calibration may be checked using the procedure on the preceding page. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-5 Serial I/O Analog Input Points The procedure for checking and calibrating serial I/O analog input points is given below. An input point includes the FIC and the Analog Input Block (AIB). Calibration constants are stored on the FIC. Figure 8.1.3 shows the I/O Block Configuration screen used in the calibration procedures. Address I/O BLOCK CONFIGURATION Device Type AIB =10AD101 Block Tag Þ Field Value -15.29 -15.29 25-Jan-90 10:42:34 Block Type ÞAIB Mode ®MANUAL Auto Lock Þno Filt Time Þ None Block Out Eng Units Þ Sig Char ÞNone Eng Zero Þ.00 Lo Cutoff Þ.00 .00 Calibrate ®None Nom Out Eng Max Þ100.00 >None Inst Bias ®.00 ALARMS Inst High ®None Crit High ® None Adv High ®None Inst Low ®None Crit Low ® None Adv Low Hardware Alarm Code 0 Priority Þ0 Plant UnitÞ0 ®None Al DdBand Þ1.00 CONFIG 1 Figure 8.1.3. I/O Block Configuration Screen (AIB) RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-6 Checking Calibration of Serial I/O Analog Input Points - To check calibration of serial I/O analog input points: 1. If there is I/O redundancy, remove the redundant Field Interface Card (FIC) from service. 2. Disconnect the FIC input field wiring at the marshaling panel and replace it with a Rosemount 262 Field Calibrator (set up as a current source). Select button 4. See Figure 8.1.4. 101 A 102 B A 103 B A B Rosemount 262 Figure 8.1.4. Connecting a Meter for Input Calibration 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 4. Set the Rosemount 262 Field Calibrator for 4.000 mA output. 5. The “Field Value” of the I/O Block Configuration screen must read 0.000 ±0.10%. 6. Set the Rosemount 262 Field Calibrator for 20.000 mA output. 7. The “Field Value” of the I/O Block Configuration screen must read 100 ±0.10%. 8. Calibrate the analog input point if the values in “Field Value” are not within the specified range during the checking procedure. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-7 Calibrating Serial I/O Analog Input Points NOTE: Before calibration of any point is performed, it is recommended that the accuracy of the calibration device be checked carefully. - To calibrate a serial I/O analog input point: 1. If there is I/O redundancy, remove the redundant Field Interface Card (FIC) from service. 2. Disconnect the FIC input field wiring at the marshaling panel and replace it with a Rosemount 262 Field Calibrator (set up as a current source). Select button 4. See Figure 8.1.4. 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 4. Set the Rosemount 262 Field Calibrator to 4.000 mA. 5. Cursor to the “Calibrate” field and use [NEXT OPTION] to get “Cal Low” in the “Calibrate” field. Press [ENTER]. 6. Use [NEXT OPTION] to get “Cal High” in the “Calibrate” field. 7. Set the Rosemount 262 Field Calibrator to 20.000 mA. Press [ENTER]. The FIC will go through an internal calibration process. 8. Replace the field wiring and return the block mode to AUTO. NOTE: Calibration may be checked using the procedure on the preceding page. RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-1-8 RS3: Calibration Calibrating Serial I/O Field Interface Cards SV: 8-2-1 Section 2: Calibrating Temperature Input FICs This section covers the calibration and checking of Temperature Input Field Interface Card (FIC) 1984--2731--000x. Check the calibration of Temperature Input FICs during periodic maintenance. Calibrate a Temperature Input FIC if: D The “Default Calibration” alarm is active. D A calibration check shows that the input readings are inaccurate. D An ohm, Resistance Temperature Detector (RTD), or Cold Junction Compensator (CJC) FIC is moved from one location to another. D The field wiring is changed. Each FIC has two independent input channels. Either channel may be used for millivolt or ohm sensors at either Range 1 or Range 2. Only the sensor type and range actually used is to be calibrated. The calibration procedure used for resistive (ohm) sensors corrects for the effect of field wiring. Recalibrate this type whenever the field wiring is changed or the FIC is moved to another slot. Table 8.2.1 and Table 8.2.2 list the calibration values for ohm and millivolt sensor types. Table 8.2.1. Calibration Resistance for Ohm Sensor Types Range Calibration Value Resistance Tolerance Range 1 Lo Hi 0.0 Ohm 100 Ohm -±.01% Range 2 Lo Hi 0.0 Ohm 400 Ohm -±.01% Table 8.2.2. Calibration Voltage for Millivolt Sensor Types RS3: Calibration Range Calibration Value Voltage Tolerance Range 1 Lo Hi --4 mV 22 mV .02% .02% Range 2 Lo Hi --16 mV 88 mV .02% .02% Calibrating Temperature Input FICs SV: 8-2-2 Temperature Input FIC Calibration Procedure The following equipment is required to calibrate a Temperature Input Block (TIB) FIC: D D Decade resistor box or precision resistors of 100, and 400 ohms ±.01%. A piece of wire can be used for 0.0 ohms. Precision millivolt source capable of --16 to +88 mV with an accuracy of ±.02% Figure 8.2.1 shows the TIB I/O Block Configuration screen for calibrating a millivolt sensor. When you are calibrating an existing TIB block, the display scaling values and the CJC link are retained. Indicates the calibration sequence configured: “Lo --4 mv” Sensor TypeÞMV, OHM Address I/O BLOCK CONFIGURATION Device Type TIB =10AB101 Block Tag Þ 25-Mar-89 10:42:34 Default Calibration Block Type ÞTIB Mode ®MANUAL Auto Lock Þno Sensor Type ÞMV Block Out Eng Units Temp >C Range Eng Zero 0. Ext. Res 0. Offset Cal No Calibrate ÞLo -4 mv Field Value -15.29 C -15.29 Eng Max 100.0 Descriptor Þ .00 >1 Cal High Value Required -4.250 to 22.500 mv ALARMS Inst High ®None Crit High ® None Adv High ® None Inst Low ®None Crit Low ® None Adv Low ® None Hardware Alarm Code 8 Priority Þ0 Plant UnitÞ0 Al DdBand Þ None 10:40:21 =10AB101 Default Calibration Used CONFIG 1 Indicates whether a low or high calibration range is also needed. Figure 8.2.1. Calibrating a Millivolt Sensor RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-3 - To calibrate a Temperature Input FIC partially: 1. Call up the appropriate I/O Block Configuration screen and set the Mode to MANUAL. 2. Cursor to the “Cal Mode” field and press [NEXT OPTION] to select “Yes”, and then press [ENTER]. The field changes to “Calibrate”. 3. Cursor away from the field and then back to the “Calibrate” field. Press [NEXT OPTION] to select the “Lo” calibration option. 4. Input the exact input voltage or resistance to be calibrated (as displayed below the “Calibrate” field). Wait 10 seconds for the reading to stabilize, and then press [ENTER]. 5. Repeat the process for the “Hi” calibration option. 6. If when calibrating an mV sensor the millivolt generator displays an unstable reading, disconnect one lead of the device temporarily until the voltage is established, and then connect the lead and repeat the step. 7. After performing both the low and high calibration options, the “Default Calibration“ alarm disappears. If the “Default Calibration” alarm does not disappear, repeat the calibration procedure and be sure to use the correct input voltage or resistance. 8. Cursor to the “Mode” field and press [NEXT OPTION] to select AUTO, and then press [ENTER]. RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-4 - To calibrate an ohm, RTD, or CJC FIC: NOTE: For best accuracy, we recommend that you field mount the calibration resistor (if practical), rather than connect it to the Analog Marshaling Panel. Connect the device as close to the sensor as practical to ensure that field wiring resistance is corrected during calibration. 1. Call up the appropriate I/O Block Configuration screen. Set the mode to MANUAL. 2. For an RTD block, set “Ext. Res” to zero. 3. Remove the FIC being calibrated. This prevents it from detecting a burnout state when the field wiring is disconnected. Pull it out far enough to disengage the edge connector on the card. 4. Replace the sensor with the appropriate precision resistor. Connect the resistor as close to the sensor as possible. The high value will be calibrated first. This is 100 ohms for Range 1 or 400 ohms for Range 2. 5. Reinsert the FIC. 6. Cursor to the “Cal Mode” field and press [NEXT OPTION] to display “Yes”, and then press [ENTER]. The field changes to “Calibrate”. 7. Cursor away from the field and then back to the “Calibrate” field. Press [NEXT OPTION] to select the “Hi” calibration option. Wait for the “Field Value” field to stabilize at the resistor value. Press [ENTER] to activate the high end calibration. NOTE: The field Value may slowly drift up or down to the steady state. Do not press [ENTER] until the reading is stable. 8. Change the calibration resistor to zero ohms by shorting the resistor with a piece of wire. Do not open the wiring connections when shorting the resistor or the FIC will detect a burnout state. 9. Cursor to the “Calibrate” field and use [NEXT OPTION] to select the “lo” calibration option. Wait for the “Field Value” to stabilize at zero, then press [ENTER] to activate the low end calibration. 10. Cursor to the “Offset Cal” field and use [NEXT OPTION] to set it to “Yes”. Wait until the “Field Value” stabilizes before pressing [ENTER]. The “Offset Cal” field will change back to “No”. 11. Remove the FIC and restore the field wiring. Reinsert the FIC. 12. Cursor to the “Mode” field, use [NEXT OPTION] to select “AUTO”, and press [ENTER]. RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-5 - To calibrate the MV FIC: NOTE: The millivolt source should be connected at the Analog Marshaling Panel. Be sure that there is no thermocouple wire in the circuit during calibration. 1. Call up the appropriate I/O Block Configuration screen. Set the mode to MANUAL. 2. Remove the FIC being calibrated. This prevents it from detecting a burnout state when the field wiring is disconnected. Pull it out far enough to disengage the edge connector on the card. 3. At the Analog Marshaling Panel, disconnect all thermocouple wire for the point and connect the millivolt source. The high value will be calibrated first: 22 mV for Range 1 or 88 mV for Range 2. 4. Reinsert the FIC. 5. Cursor to the “Cal Mode” field and press [NEXT OPTION] to display “Yes” then press [ENTER]. 6. Cursor to the “Calibrate” field and press [NEXT OPTION] to select the “Hi” calibration option. Wait for the “Field Value” field to stabilize. Press [ENTER] to activate the high end calibration. NOTE: The field Value may slowly drift up or down to the steady state. Do not press [ENTER] until the reading is stable. 7. Change the calibration voltage to the low value: --4 mV for Range 1 or --16 mV for Range 2. Do not open the wiring connections or the FIC will detect a burnout state. 8. Cursor to the “Calibrate” field and use [NEXT OPTION] to select the “Lo” calibration option. Wait for the “Field Value” to stabilize, and then press [ENTER] to activate the low end calibration. 9. Remove the FIC and restore the field wiring. Reinsert the FIC. 10. Cursor to the “Mode” field, use [NEXT OPTION] to select “AUTO”, and press [ENTER]. RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-6 Thermocouple Sensor Calibration Verification Immediately following the calibration of a thermocouple TIB, the TIB is evaluated using the cold junction compensation value. To verify calibration, change the “Cal Mode” to “Yes”. This will disable the cold junction compensation link and allow for verification of the calibration. The cold junction compensator link is re-enabled by putting the TIB in AUTO mode. RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-7 Thermocouple Sensor Redundancy Use of other than 1:1 redundancy will result in a slight loss of accuracy when the redundant FIC is in service. This is due to the Analog Transfer Card relays and wiring, which are introduced into the circuit when the redundant FIC is in service. If you are using software at V15 or lower, calibrate the redundant FIC to work best with the most critical reading that it backs up. Software at V16 and higher uses a per-point offset factor stored in the NV memory. When the backup FIC takes over, it uses the correct offset factor, which corrects for the field wiring of the point. If you are going to use a temperature input FIC as a redundant FIC, you need to calibrate only the low and high ranges that the redundant FIC is backing up. NOTE: After calibrating a TIB, be sure to calibrate the corresponding Redundant Input/Output Block (RIOB) if one exists. An RIOB can be calibrated by backing up a calibrated TIB, and then performing the calibration procedure. RS3: Calibration Calibrating Temperature Input FICs SV: 8-2-8 RS3: Calibration Calibrating Temperature Input FICs SV: 8-3-1 Section 3: Calibrating Pulse Input FICs This section covers the calibration of the Pulse Input Field Interface Card 1984--1587--000x. Figure 8.3.1 shows the components of a Pulse Input Field Interface Card. ZERO ADJUST SPAN ADJUST CAL R40 FREQ SELECT 300 500 NORM 1K DDS R41 3K DS1 10K 20K DS2 1234 TP1 VOLT SELECT 30V 10V 5V 2V .5V .05V VOLTAGE OUTPUT TP2 F3 F2 F1 Figure 8.3.1. Pulse Input Field Interface Card RS3: Calibration Calibrating Pulse Input FICs SV: 8-3-2 Pulse Input FICs Calibration Procedure NOTE: Be sure that the frequency source is accurate and stable over time. - To calibrate a Pulse Input Field Interface Card: 1. Record the position of the FREQ SELECT jumper (HD1--HD7). Select the full-scale frequency to be used by placing the FREQ SELECT jumper (HD1--HD7) in the proper position. 2. Record the position of the VOLT SELECT jumper (HD8--HD13). Set the VOLT SELECT jumper (HD8--HD13) to match the voltage level produced by the frequency source. 3. Using an analog FIC extender board (part number 1984--1362--000x), insert the pulse input FIC into the card cage and allow it to warm up for at least one minute. 4. Be sure that the output voltage measured across across TP1 and TP2 of the pulse input FIC is stable. The output should not vary by more than .0005 volts. If it varies by more than this amount, allow it to warm up a few more minutes and try again. 5. Apply the full-scale frequency to the input of the FIC. 6. Hold the switch in the CAL position. 7. Adjust R40 until the voltage across TP1 and TP2 is approximately 4.00 volts. 8. Release the switch. Adjust R41 until the output voltage is approximately 5.00 volts. 9. While holding the switch in the CAL position, use the SPAN ADJUST pot (R22) to adjust the output voltage to 4.0000 volts (± 0.0001). If R22 bottoms out, use R41 as a coarse adjustment. NOTE: Accuracy of the pulse input FIC will probably be affected over time, mostly by the calibration potentiometers R40 and R41. These are high resistance potentiometers with few turns and will be more sensitive than R5 and R22. The best way to minimize their effect is to decrease R40 and R41 and increase R5 and R22 as much as possible when calibrating the card. RS3: Calibration Calibrating Pulse Input FICs SV: 8-3-3 10. Release the switch. Use the ZERO ADJUST pot (R5) to adjust the output to 5.0000 volts (± .0001). If R5 bottoms out use R40 as a course adjustment. 11. Remove the input signal. The output should read 1.0000 volts (± .0002). If it does, calibration is complete. If not, complete the remaining steps. 12. Use the ZERO ADJUST pot (R5) to adjust the output to the value found by using the formula: V’ = 1+ (1 -- V) / 2 where: V = present output V’ = newly adjusted output 13. Apply the full-scale frequency to the input. Use the SPAN ADJUST pot (R22) to adjust the output to 5.0000 volts (± .0002). 14. Remove the input signal. The output should read 1.0000 volts (± .0002). If it does, calibration is complete. If not, repeat steps 9 through 11 again. 15. Restore the FREQ SELECT jumper (HD1--HD7) and the VOLT SELECT jumper (HD8--HD13) to their original positions. RS3: Calibration Calibrating Pulse Input FICs SV: 8-3-4 RS3: Calibration Calibrating Pulse Input FICs SV: 8-4-1 Section 4: Calibrating MUX FEMs This section covers calibration and checking calibration of voltage, current, and RTD multiplexer Front End Modules (FEMs). These calibration procedures apply to the FEMs shown in Table 8.4.1. Table 8.4.1. Multiplexer Front End Modules FEM Characteristics Range Calibration Accuracy 1984--0607--0001 Thermocouple and mV FEM 20 mV .25% 1984--0607--0003 RTD FEM 80 mV .13% 1984--0607--0004 Reed Relay FEM, 4--20 mA 400 mV .11% 1984--0607--0007 Universal Reed Relay FEM 2 Volt .11% 1984--0607--0009 Reed Relay RTD FEM 4--20 mA .4% CAUTION Always turn the MUX power supply OFF when inserting or removing FEMs. Calibration correction constants are calculated and used in the Multiplexer FlexTerm. Calibration constants are also stored in the Nonvolatile Memory card for reloading to the FlexTerm after a power loss. Calibration constants are normally entered into the Multiplexer Controller by copying numbers written on the Front End Module (FEM) label into the Multiplexer Input Block (MIB) during system start up or after controller configuration is cleared by the Kill Controller or Wipe Bubble functions. Calibration constants should also be changed if a FEM is replaced. This is done by entering the values that are recorded on the label of the new FEM into the appropriate MIB screen fields. Recalibrating or re-entering the calibration values is not necessary if the Multiplexer Controller, FlexTerm Comm card, or Power Supply card is replaced. RS3: Calibration Calibrating MUX FEMs SV: 8-4-2 NOTE: The valid ranges for calibration constants are: 0.50000 to 0.65535 and 1.00000 to 1.50000. Each FEM is calibrated at the factory and the necessary calibration constants are recorded on a label. Resistance Temperature Detector (RTD) FEMs, however, require no calibration because they contain a very precise internal resistor and calibration is constantly checked and corrections are made for any drift. Calibration accuracy can be improved, if necessary, by recalibrating at shorter intervals and using high accuracy equipment. Entering Calibration Constants for Multiplexer FEMs 1. Call up the Multiplexer Input Block (MIB) screen for any point on the FEM to be calibrated (preferably a midpoint address). If an MIB is not configured at that address, configure one. 2. Set the block to manual. 3. Cursor to the “Sig Char” field. NOTE: Write down the characteristic shown in the “Sig Char” field of the MIB screen or print the screen so you can reenter the proper scale upon completion of the calibration of this FEM. 4. Select the scale to calibrate. On a 4--20 FEM, this would be 4--20 mA. 5. Cursor to the Calibrate field, and press [NEXT OPT] until “Enter Const” appears, and then press [ENTER]. 6. Cursor to the Cal Const field, and enter the exact value written on the FEM label for that scale, and then press [ENTER]. 7. If other scales on this FEM will be used, enter the constants for those scales also. Enter all scales on the same MIB. RS3: Calibration Calibrating MUX FEMs SV: 8-4-3 Calibrating Voltage Input and Thermocouple FEMs All scales on the Voltage Input and Thermocouple FEM (1984--0607--0001 and 1984--0607--0007) are calibrated using four voltage scales, 20 millivolts (mV), 80 mV, 400 mV and 2 volts. If these four ranges are calibrated, all thermocouple and voltage ranges will be correctly calibrated. Figure 8.4.1 shows the calibration setup for the Voltage and Thermocouple FEM calibration. To calibrate the voltage FEMs, a stable voltage source in the 20 millivolt to 2 volt range is needed along with an accurate 4 1/2 or 5 1/2 digit digital voltmeter. The better the equipment used, the more accurate the results will be. A thermocouple calibration device that also has a voltage scale is an ideal source. If any scale is not normally used in any particular FEM, that scale does not need to be calibrated. Each FEM must be checked and calibrated separately, but only one input of each FEM need be checked or calibrated. Point 10 should be used if possible because it is in the center of the point range on the FEM. However, any point that is not in use will work satisfactorily. Voltage and Thermocouple FEM Calibration Constants 81 61 41 21 1 100 80 60 40 20 POINT 10 20.000 mV Digital Voltmeter 5 1/2 Digit 20 mV 80 mV 400 mV Stable low voltage power supply or thermocouple calibration device 2 volts Figure 8.4.1. Voltage and Thermocouple FEM Calibration RS3: Calibration Calibrating MUX FEMs SV: 8-4-4 It is not necessary to calibrate all scales on a FEM that uses only one scale. Thermocouples use the 20 and 80 mV ranges and 4--20 mA uses the 400 mV range. To determine which scale needs to be calibrated, put the MIB in manual and cursor to the “Calibrate” field. Press [NEXT OPT] until “Display” appears and then press [ENTER]. The scale that appears just below the “Display” indication is the scale that would need to be calibrated. Other scales in that FEM can be checked in a similar manner. Few system installations use the 2 or 20 volt ranges. You may, at your option, choose not to calibrate the 2 volt range. Any unused ranges left uncalibrated will not affect system operation nor will they create any alarms. RS3: Calibration Calibrating MUX FEMs SV: 8-4-5 Checking and Calibrating Voltage Input and Thermocouple FEMs - To check and calibrate Voltage Input and Thermocouple FEMs: 1. Connect a voltage source to an input of the FEM to be calibrated as shown in Figure 8.4.1. Replace the FEM cover, install it in the FlexTerm, and fasten the ground lug at the bottom of the FEM. 2. Call up the appropriate I/O Block Configuration (MIB) screen and set it to MANUAL. 3. Cursor to the “Sig Char” field. NOTE: Write down the characteristic shown in the “Sig Char” field of the MIB screen or print the screen so you can reenter the proper scale at the completion of the calibration of this FEM. 4. Press [NEXT OPT] until the 20 mV scale appears and then press [ENTER]. 5. Verify that the “Default Calibration” indication is not active on the MIB screen. If it is active, use the following procedure to enter the constants for this scale. If no calibration value is listed on the FEM, proceed to step 6. 6. Cursor to the “Calibrate” field and press [NEXT OPT] until “Enter Const” appears. a. Enter the exact value written on the FEM label in the “Cal Const” field for this scale. b. Adjust the output of the voltage source to exactly 20.000 mV. The “Field Value” on the MIB screen should read between 19.975 and 20.025 mV. If the calibration is satisfactory, proceed to step 10. 7. Cursor to the “Calibrate” field and press [NEXT OPT] until “CAL HIGH” appears. 8. Verify that exactly 20.000 mV is still going into the input of the FEM and press [ENTER]. 9. Write the new value from the “Cal Const” field on the FEM label for future reference. NOTE: If any calibration constant is greater than 1.50000 or less than 0.50000, the voltage used in the calibration procedure was incorrect or the FEM is bad and should be replaced. The valid ranges for calibration constants are: 0.50000 to 0.65535 and 1.00000 to 1.50000. RS3: Calibration Calibrating MUX FEMs SV: 8-4-6 10. Repeat Steps 4 through 9 for the 80 mV, 400 mV, and 2 volt scales. In steps 4 and 8 use 80.000 mV, 400.00 mV, or 2.0000 volts as required. Calibration specifications for step 6 should be between: 79.950 to 80.050 mV 399.80 to 400.20 mV 1.9990 to 2.0010 volts. 11. After all scales have been calibrated, correct the “Sig Char” by changing it back to what it was before you began the procedure. 12. Restore the “Sig Char” field of the MIB screen to the value recorded in step 3. 13. Put the MIB screen back into AUTO Mode. “Cal Low” is automatically calibrated within the FEM. This completes the calibration for this FEM. RS3: Calibration Calibrating MUX FEMs SV: 8-4-7 Calibrating 4--20 mA FEMs Only the 400 millivolt scale of each 4--20 mA FEM needs to be calibrated. The 1984--0607--0004 FEM has internal 20 ohm resistors. This FEM type can be calibrated using the Rosemount 262 Field Calibrator or other suitable current source. Figure 8.4.2 shows the calibration connections for the 1984--0607--0004 4--20 mA FEM. 4--20 mA FEM 81 61 41 21 1 Point 10 100 80 60 40 20 Calibration Constants Rosemount 262 Select #2 on the 262 Calibrator Figure 8.4.2. 4--20 mA FEM Calibration for 1984--0607--0004 RS3: Calibration Calibrating MUX FEMs SV: 8-4-8 Checking and Calibrating the 4--20 mA FEM - To check and calibrate a 4--20 mA FEM: 1. Connect a current source to an input of the FEM to be calibrated. Replace the FEM cover and install it in the FlexTerm and fasten the ground lug at the bottom of the FEM. See Figure 8.4.2. 2. Call up the appropriate I/O Block Configuration screen (MIB) and set the Mode to MANUAL. 3. Verify that the Default Calibration indicator is not active on the MIB screen. If it is, use the following procedure to enter the constants. If no calibration value is listed on the FEM, proceed to step 4. a. Cursor to the “Calibrate” field and press [NEXT OPT] until “Enter Const” appears. b. Enter the exact value written on the FEM in the “Cal Const” field. 4. Adjust the output of the current source to exactly 20 mA. The lower line of the “Field Value” on the MIB should read between 99.70 and 100.30%. If it does not, proceed to step 5. 5. Cursor to the “Calibrate” field and press [NEXT OPT] until “Cal High” appears. 6. Verify that exactly 20 mA is still going into the input of the FEM and press [ENTER]. 7. Write the new value in the “Cal Const” field on the FEM label for future reference. NOTE: If the calibration constant is greater than 1.50000 or less than 0.50000 the current used in the calibration procedure was incorrect, or the FEM is bad and should be replaced. The valid ranges for calibration constants are: 0.50000 to 0.65535 and 1.00000 to 1.50000. “Cal Low” is automatically calibrated within the FEM. This completes the calibration for this FEM. RS3: Calibration Calibrating MUX FEMs SV: 8-4-9 Checking Calibration of RTD FEMs The calibration of RTD FEMs should be checked periodically along with the other FEMs even though RTD FEMs require no calibration. The procedure below includes both the 1984--0607--0003 Solid State FEMs and 1984--0607--0009 Reed FEMs. Figure 8.4.3 shows the connections to be made when calibrating a RTD FEM. A precision resistor should be used. This resistor should be preferably a 100 to 200 ohm 0.01% tolerance. A metal film resistor of any value between 100 and 300 ohms will work if an accurate meter is available to read its exact value. The resistor to be used is connected to one input (preferably in the middle of the FEM inputs) of the RTD FEM. 61 41 21 1 RTD FEM 80 60 40 20 4 WIRE SETUP POINT 10 V+ I+ V-- I-- 3 WIRE SETUP POINT 10 V+ I+ V-- I-- PRECISION RESISTOR OR RESISTOR OF KNOWN VALUE Figure 8.4.3. RTD FEM Calibration Check RS3: Calibration Calibrating MUX FEMs SV: 8-4-10 Checking RTD FEM Calibration NOTE: It is necessary for the controller to be in NORMAL status (Overview ControlFile screen). The individual block should be in MANUAL mode to check calibration. - To check RTD FEM calibration: 1. Connect a resistor to an input of the FEM to be calibrated as shown in Figure 8.4.3. Replace the FEM cover, install it in the FlexTerm, and fasten the ground lug at the bottom of the FEM. 2. Call up the appropriate I/O Block Configuration (MIB) screen and set the Mode to MANUAL. 3. Cursor to the “Sig Char” field. NOTE: Write down the characteristic from the “Sig Char” field or print the screen so you can reenter the proper scale after calibrating the FEM. 4. Press [NEXT OPT] until “3 W Ohms” or “4 W Ohms” (depending on which setup is used) is displayed and press [ENTER]. 5. Verify that the “Field Value” reads the correct resistance value. If it does not, first recheck the value of the resistor, and if it is correct, replace the FEM. RTD FEMs cannot be recalibrated. 6. After the RTD FEM has been checked, restore “Sig Char” to the original value. 7. Set the block back to AUTO Mode. This completes the calibration check for this RTD FEM. RS3: Calibration Calibrating MUX FEMs SV: 8-5-1 Section 5: Calibrating Analog I/O Field Interface Cards This section covers calibration of the Analog I/O Field Interface Cards (FICs) listed in Table 8.5.1. Analog I/O Field Interface Cards are housed in a Multi-Strategy or Single-Strategy FlexTerm and are connected to a MultiLoop or Single-Strategy Controller Processor in the ControlFile. CAUTION The calibration procedures in this section apply only to the FICs listed in Table 8.5.1. Table 8.5.1. Analog I/O Field Interface Cards FIC Characteristics Range Calibration Accuracy 1984--1394--000x Non-Isolated Input FIC 4--20 mA 0.1% 1984--1463--000x Non-Isolated Input FIC 4--20 mA 0.1% 1984--1325--000x Isolated Input FIC 4--20 mA 0.2% 1984--1466--000x Isolated Input FIC 4--20 mA 0.2% 1984--1420--000x Isolated Voltage Input FIC 1--5 volt 0.2% 1984--1273--000x Non-Isolated Output FIC 4--20 mA 0.3% 1984--1490--000x Non-Isolated Output FIC 4--20 mA 0.3% 1984--1334--000x Isolated Output FIC 4--20 mA 0.5% 1984--1469--000x Isolated Output FIC 4--20 mA 0.5% Analog I/O uses analog voltages to communicate data between the Controller Processor card and the FIC. An analog input FIC drops the field input 4--20 mA current across a precision resistor to get a 1--5 volt analog value. This analog value is transmitted to the ControlFile when the Controller Processor card uses an Analog/Digital (A/D) converter to digitize the value. An analog output FIC receives a 1--5 volt analog value from the Controller Processor card and uses an internal A/D converter to generate the 4--20 mA field current. The output FIC drops the 4--20 mA field current across a precision resistor to generate a .5--2.5 volt analog feedback signal. The analog feedback signal is sent to the Controller Processor where it is converted to digital form and compared with the original value. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-2 Calibration correction constants for each input and output loop are stored within the Controller Processor card. The calibration procedure redefines the calibration correction constants. Calibration is done through the operator console I/O Block Configuration screens using Rosemount 262 Field Calibrator. Alternatively, a calibrated current source may be used for the inputs and a precision meter may be used for the outputs. All Controller Processor cards are calibrated at the factory so field calibration of Controller Processor cards should not be necessary. Controller A/D converters are checked constantly for drift as part of the Controller’s normal operating routine. It is very rare that a Controller Processor A/D converter drifts to any extent. If two or more adjacent blocks exhibit a large amount of drift, the Controller Processor Card should be replaced. The resistor on the FIC may be subject to drift, so calibration of each input and output point should be should be checked at 6-month intervals. Calibration is not required when a FIC is replaced. However, calibration of inputs may be desirable if highest accuracy is desired. The procedures described below use a Rosemount 262 Field Calibrator. This provides 0.1 percent accuracy, which is sufficient for most purposes. If higher accuracy is required, a precision resistor can be used in the output loop and an accurate Digital Volt Meter (DVM) (4--1/2 or 5--1/2 digit display) can be used to read the voltage drop across the resistor. The current can then be calculated using Ohm’s Law. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-3 Analog I/O Output Points The analog I/O output point includes the Field Interface Card (FIC) and the Controller Processor card. Figure 8.5.1 shows the I/O Block Configuration screen for an analog output point. CAUTION The calibration procedure for the AOB will output zero and full-scale readings from the output FIC. The field device must be disconnected from the circuit. Using the analog extender card in the CALIBRATE position will bypass all current to the test points. I/O BLOCK CONFIGURATION Address =1AA103 25-Jan-90 10:42:34 Device Type AIB or AOB Block Tag Þ Block Type ÞAOB Mode Auto Lock Source Þ ® MANUAL Þ no Actual Value Value .00 Reverse Acting Þno Eng Units Output Value > .00 .00% Calibrate Alarm Priority Þ0 Plant Unit Þ0 Hardware Alarm Code 8 Fail Safe Jumper Hold -.00 ® None 0% Value 4. ma 100% Value 20. ma Output Card Rev 2.1 CONFIG 1 Figure 8.5.1. AOB Block Configuration Screen NOTE: Using an Analog Extender card (1984--1362--000x) with the switch in the CAL position eliminates the need to disconnect the field wiring to check or recalibrate an output point. NOTE: Special procedures are required for the 1984--1525--000x Isolated Output Field Interface Card. These procedures are covered in this section after the procedures for the other cards. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-4 Checking Calibration of Analog I/O Output Points An analog output Field Interface Card (FIC) is calibrated from an AOB screen. The current produced from the output FIC at 0% is read on a meter and the value (in milliamps) is entered in the “0% Value” field. The output is then set to 100% (full scale) and the meter reading is entered in the “100% Value” field. The CALIBRATE function is entered last. The system will output the corrected 4.00 and 20.00 mA current. The voltage drop across the internal precision resistor is measured by the Controller Processor A/D converter for both readings. Calibration constants are calculated and stored on the Controller Processor card. - To check analog I/O output point calibration: 1. Place the FIC on an analog extender card and move the switch to the calibrate position. Connect a Rosemount 262 Field Calibrator as shown in Figure 8.5.2. 2. Call up the appropriate I/O Block Configuration screen and set the Mode to MANUAL. 3. Cursor to the “Output Value” field and enter 0 (or the equivalent minimum scaled value). 4. The meter should read between 3.95 and 4.05 mA for a non-isolated FIC or 3.92 and 4.08 mA for an isolated FIC. 5. Enter 100 % (or the equivalent maximum scaled value) in the “Output Value” field. 6. The meter should read between 19.95 and 20.05 mA for a non-isolated FIC or 19.92 and 20.08 mA for an isolated FIC. 7. Calibrate any point with readings that fall outside the specified range. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-5 Output FIC Analog Extender Card CAL MultiLoop or SIngle-Strategy FlexTerm Rosemount 262 Select #1 on 262 Calibrator for All Output Figure 8.5.2. FIC Calibration Setup for Current Output RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-6 Calibrating Non-Isolated Analog I/O Output Points NOTE: Calibration of an analog output point should not change in normal operation. Before changing calibration on an analog output point, replace the output FIC with a good card to determine if the calibration change is caused by a faulty card. - To calibrate a non-isolated analog output point: 1. Place the FIC on an analog extender card and move the switch to the “CALIBRATE” position. 2. Connect a Rosemount 262 Field Calibrator as shown in Figure 8.6.1. Configure the Field Calibrator as a meter. 3. Call up the appropriate I/O Block Configuration screen and set the Mode to MANUAL. 4. Move the cursor to just above the “Calibrate” field on the screen. Press the [NEXT OPT] button until “Cal Low” appears, and then press [ENTER]. The cursor will move to the “0% Value” field and the FIC will generate a 4 mA current. 5. Enter the exact current reading from the field calibrator into the “0% Value” field. (You must use a decimal point.) Press [ENTER]. 6. The cursor will move to the “100% Value” field and the FIC will generate a 20 mA current. 7. Enter the exact current reading from the field calibrator into the “100% Value” field. Press [ENTER]. 8. The system will begin the Calibrate function. The “Calibrate” field will change to “Calibrate”. The FIC will generate exactly 4.00 mA and then exactly 20.00 mA. The internal calibration correction factors for the feedback resistor will be calculated and permanently stored in the internal memory of the Controller Processor Card. Wait for the “Calibrate” field to change to “None”. CAUTION Do not disconnect the meter from the circuit until the word “None” appears in the “Calibrate” field. If the meter is disconnected too early, the calibration sequence will not be completed and improper calibration constants will be entered into the Controller’s internal memory. 9. Return the FIC to its place in the FlexTerm. 10. Set the I/O block to AUTO mode. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-7 Calibrating Isolated Output FICs NOTE: The calibration procedure for the 0--20 mA Isolated Output Field Interface Card (1984--1525--000x) must be modified because there is no live zero and the calibration screen expects a value near 4 mA, rather than 0 mA. - To change Isolated Output calibration: 1. Take the output out of service (i.e., either block the valve or perform the calibration procedure in an unused slot). 2. Call up the appropriate I/O Block Configuration screen and set it in MANUAL mode. 3. Cursor to the “Calibrate” field and use [NEXT OPT] to get “Cal Low” in the calibration field. The cursor will jump to the “0% Value” field. 4. Measure the loop current with an accurate milliameter. a. If the current is more than 10 microamperes (.010 mA), enter the measured value plus 4 milliamperes in the “0% Value” field. Press [ENTER]. Proceed to step 5. b. If the measured current is less than 10 microamperes (.010 mA), enter 3.9 in the “0% Value” field. Press [ENTER]. Proceed to step 5. 5. The “Calibrate” field will change to “Cal High” and the cursor will jump to the “100% Value” field. 6. Enter the measured current reading into the “100% Value” field. Press [ENTER]. 7. If step 4b was performed, go back to step 3. If the output was near calibration, only one iteration should be necessary. If the output was not near calibration, two or three iterations may be required. If step 4b is performed three times and the loop current is still less than 10 microamperes, there is a hardware problem. 8. Check the calibration by setting the output current to 1% of span. Check for an output current sufficiently close to 0.20 mA. Also, check that the output current at 100% of span is sufficiently close to 20.00 mA. This procedure should calibrate the end points to within 0.1% or 20 microamperes of the expected value at 1% and 100%. If the values are out of this range, repeat the calibration procedure. 9. The Analog Output Block (AOB) can be returned to AUTO mode and the output can be placed back in service. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-8 Analog I/O Input Points The analog I/O input point includes the Field Interface Card (FIC) and the associated Controller Processor card. Figure 8.5.3 shows the I/O Block Configuration screen used for calibration. Address I/O BLOCK CONFIGURATION Device Type AIB =10AD101 Block Tag Þ Field Value -15.29 -15.29 10:42:34 Block Type ÞAIB Mode ®MANUAL Auto Lock Þno Filt Time Þ None Block Out Þ None Calibrate ®None Nom Out >None Eng Units Þ Sig Char Eng Zero Þ.00 Lo Cutoff Þ.00 Eng Max Þ100.00 Descriptor Þ 25-Jan-90 >.00 Inst Bias ®.00 ALARMS Inst High ®None Crit High ® None Adv High ®None Inst Low ®None Crit Low ® None Adv Low ®None Hardware Alarm Code 8 Priority Þ0 Plant UnitÞ0 Al DdBand Þ1.00 Figure 8.5.3. I/O Block Configuration Screen (AIB) CAUTION All measurement requirements from the Analog Input Block (AIB) should be disconnected from the process. If calibration is checked with the block in AUTO, do so only with the process OFF. Zero and full-scale readings could upset an operating process. With the AIB in MANUAL, the destination block input link will hold the last value before the AIB was put in manual. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-9 Checking Calibration of Analog I/O Input Points NOTE: Using an Analog Extender card (1984--1362--000x) with the switch in the CAL position eliminates the need to disconnect the field wiring to check or calibrate an input point. - To check AIB calibration: The following procedures apply to both current and voltage input FICs. 1. It is necessary to determine the jumper position on the input FIC to select the proper lead polarity and to switch the setting on the Rosemount 262 Field Calibrator. 2. Place the FIC on an Analog Extender card and move the switch to the CAL position. 3. Turn the field calibrator on and adjust the output for exactly 4.00 mA (0.00%). The switch on the left side of the calibrator can be moved to the “4 mA” position. 4. Call up the appropriate I/O Block Configuration screen and set the Mode to MANUAL. 5. Record the value shown in the “Inst Bias” field. Set the value to .00. 6. The “Field Value” on the I/O Block Configuration screen should display between --0.10 and +0.10% for non-isolated FICs or --0.20 and +0.20% for isolated FICs. 7. Change the field calibrator to exactly 20 mA (100.00%). The switch on the left side of the calibrator can be moved to the “20 mA” position. 8. The “Field Value” should read between 99.90 and 100.10% for non-isolated FICs or 99.80 and 100.20% for isolated FICs. 9. If the readings are outside these ranges, you may wish to recalibrate the point. See the calibration procedures below. 10. Restore the value of the “Inst Bias” field to the value recorded in step 5 and put the AIB Mode back to AUTO. 11. Replace the FIC in its slot. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-10 Calibrating Analog I/O Input Points The analog I/O input points can be calibrated with a current input or a voltage input. The calibration procedure is the same for either input method. The setup will be shown for current input and for voltage input and then the calibration procedure will be given. Calibrating Analog I/O Input Points Setup Using Current Input The RMT 262 Field Calibrator provides 0.1 percent accuracy which is sufficient for most purposes. For more accuracy a precision resistor (.01%) can be inserted in the loop and an accurate digital volt meter can be used to monitor the voltage across the resistor. Figure 8.5.4 shows a Current Input Field Interface Card calibration setup. Calibrate an analog input by providing an accurate zero scale input (4.00 milliamps) to enter the Cal Low function. A full scale input (20 mA) is needed to enter the CALIBRATE HIGH function. The field calibrator must be set up correctly to simulate the appropriate power conditions for the system/self-powered jumper on the card. Current Input FIC Analog Input Card CAL Rosemount 262 Select #2 on 262 Calibrator for System Powered Jumper Postion on FIC. MultiLoop or Single-Strategy FlexTerm Select #4 for Self-Powered and Use Reverse Polarity. Figure 8.5.4. Current Input FIC Calibration Setup RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-11 Calibrating Analog I/O Input Points Setup Using Voltage Input Figure 8.5.5 shows an example of a voltage Input Field Interface Card setup with a Rosemount 262 Field Calibrator. A Rosemount 262 Field Calibrator can also be used with a precision 250 ohm resistor (0.01% tolerance) connected across the input of the field calibrator. This will provide the appropriate voltage from the circuit to calibrate the voltage input FIC, but it will not be as accurate. To improve accuracy, an accurate voltmeter can be used to monitor the input voltage at the extender card test points. Calibrate voltage input FICs by using a stable voltage source with 1.000 volts applied for the Cal Low function and 5.000 volts applied for the Cal High function. Use a variable power supply capable of supplying 1 to 5 volts and an accurate digital voltmeter. Voltage Input FIC Analog Extender Card CAL Precision 250 Ohm Resistor 0.01% Tolerance Rosemount 262 MultiLoop or SIngle-Strategy FlexTerm Select #4 for Voltage Input FIC Figure 8.5.5. Voltage Input FIC Calibration Setup RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-5-12 Calibrating Analog I/O Input Points This calibration procedure applies to both the current and the voltage input techniques. NOTE: Calibration of an AIB should not change through normal operation. Before changing calibration of an AIB, verify the calibration of the Rosemount 262 (or the device being used) and replace the input FIC with a known good unit. Calibration may be changed, however, if more accuracy on the inputs is desired. CAUTION All measurement requirements from the AIB should be disconnected from the process. If calibration is checked with the block in AUTO, do so only with the process set to OFF. Zero and full-scale readings could upset an operating process. With the AIB in MANUAL, the destination block input link will hold the last value before the AIB was put in manual. - To change the calibration of an analog I/O input point: 1. Place the FIC on an extender card setup for either current or voltage input. 2. Call up the appropriate I/O Block Configuration screen and set the Mode to MANUAL. 3. Record the value shown in the “Inst Bias” field and set the field to .00. 4. Adjust the current from the field calibrator to read exactly 4.00 mA (0.00%) or set the input voltage to 1.000 volts. 5. Cursor to the “Calibrate” field and use [NEXT OP] to get “Cal Low” in the field. Press [ENTER]. 6. Adjust the field calibrator current to read 20.00 mA (100.00%) or set the input voltage to 5.000 volts. 7. Use [NEXT OP] to get “Cal High” in the “Calibrate” field. Press [ENTER]. 8. Restore the “Inst Bias” field to the value recorded in step 3. 9. Set the AIB block mode to AUTO. 10. Return the FIC to its slot. RS3: Calibration Calibrating Analog I/O Field Interface Cards SV: 8-6-1 Section 6: Calibrating Multipoint Analog I/O (MAIO) Output and Input Points This section covers calibrating and checking the calibration of the Multipoint Analog I/O (MAIO) output and input points. Checking and Calibrating MAIO Output Points - To check the calibration of an MAIO output point: 1. Remove the redundant Field Interface Module (FIM) from service by unplugging it (if a redundant FIM is installed). The RS3 will the generate the alarm “RIOB Hardware: Comm Timeout”. 2. Disconnect the FIM output field wiring at the Termination panel and replace it with a Rosemount 262 Field Calibrator (set up as an ammeter). The connection depends on whether the output point is jumpered for self power or for system power. a. Self-powered output point -- Connect the Calibrator as shown in Figure 8.6.1 and select button 1 on the Calibrator. b. System-powered output point -- Reverse the leads shown in Figure 8.6.1 and select button 3 on the Calibrator. TB15 TB16 TB17 TB15 TB16 TB17 + -- S + -- S + -- + -- S + -- S + -- =10AC516 + -- Self-Powered Output Point =10AC516 + -- System-Powered Output Point Figure 8.6.1. Rosemount 262 Field Calibrator Connection for Output Calibration RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points SV: 8-6-2 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. Figure 8.6.2 shows the I/O Block Configuration screen for an analog output point. I/O BLOCK CONFIGURATION Address =1AA103 25-Jan-90 10:42:34 Device Type AIB or AOB Block Tag Þ Block Type ÞAOB Source Þ Mode Auto Lock ® MANUAL Þ no Actual Value Value .00 Reverse Acting Þno Eng Units Output Value > .00 .00% Calibrate Alarm Priority Þ0 Plant Unit Þ0 Hardware Alarm Code 8 Fail Safe Jumper Hold -.00 ® None 0% Value 4. ma 100% Value 20. ma Output Card Rev 2.1 CONFIG 1 Figure 8.6.2. Analog Output Block (AOB) Configuration Screen 4. Cursor to the “Output Value” field and enter 0 (or the equivalent minimum scaled value). The meter reading must be 4.000+ .016 mA. 5. Enter 100 % (or the equivalent maximum scaled value) in the “Output Value” field. The meter reading must be 20.000+ .016 mA. 6. Recalibrate the analog output points if the values displayed on the meter do not fall within the 4--20mA range. NOTE: Before calibration of any point is performed, check the accuracy of the calibration device. - To calibrate an MAIO output point: 1. Remove the redundant Field Interface Module (FIM) from service (if a redundant FIM is installed). 2. Disconnect the FIM output field wiring at the Termination Panel and replace it with a Rosemount 262 Field Calibrator (set up as an ammeter). The connection depends on whether the output point is jumpered for self power or for system power. RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points SV: 8-6-3 a. Self-powered output point -- Connect the Calibrator as shown in Figure 8.6.1 and select button 3 on the Calibrator. b. System-powered output point -- Reverse the leads shown in Figure 8.6.1 and select button 1 on the Calibrator. 3. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 4. Cursor to the Calibrate field and enter the following by using Next Option: Cal Low. The cursor will jump to the 0% Value field. 5. Enter the current value displayed on the Rosemount 262 Field Calibrator in the 0% Value field. The Calibrate field will change to Cal High. 6. Cursor to the 100% Value field and enter the current value displayed on the Rosemount 262 Field Calibrator. The system begins calibrating when the Calibrate field changes to “Calibrate.” At that moment, the FIM generates exactly 4.00 mA and then 20.00 mA. The internal calibration correction factors for the feedback resistor are calculated and permanently stored in the internal memory of the FIM. Calibration is completed when the Calibrate field changes to “None.” CAUTION Do not disconnect the meter from the circuit until the word “None” appears in the Calibrate field. If the meter is disconnected too early, the calibration sequence does not complete and improper calibration constants are entered into the FIM’s internal memory. NOTE: You can check the calibration using the check calibration procedure on the preceding page. 7. Reconnect the field wiring and return the AOB to AUTO. RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points SV: 8-6-4 Checking and Calibrating MAIO Input Points - To check the calibration of an MAIO input point: 1. Remove the redundant Field Interface Module (FIM) from service by unplugging it (if a redundant FIM is installed). The RS3 will the generate the alarm “RIOB Hardware: Comm Timeout”. For best accuracy, while calibrating a desired point, the point below the point to be calibrated (the next address) should be at 50%. 2. Disconnect the FIM input field wiring at the Termination Panel and replace it with a Rosemount 262 Field Calibrator (set up as a current source). Refer to Figure 8.6.3. 3. Select button 4 on the Calibrator. 4. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 5. Set the Rosemount 262 Field Calibrator for 4.000 mA output. The Field Value field of the I/O Block Configuration screen must read 0.000 +0.10%. 6. Set the Rosemount 262 Field Calibrator for 20.000 mA output. The Field Value field of the I/O Block Configuration screen must read 100 +0.10%. 7. Calibrate the analog input point if the values in Field Value do not fall within the specified range during this calibration checking procedure. TB15 TB16 TB17 + -- S + -- S + -- =10AC716 + -- Figure 8.6.4. Rosemount 262 Field Calibrator Connections for Input Calibration RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points SV: 8-6-5 - To calibrate an MAIO input point: 1. Remove the redundant Field Interface Module (FIM) from service (if a redundant FIM is installed). 2. Disconnect the FIM input field wiring at the Termination Panel and replace it with a Rosemount 262 Field Calibrator (set up as a current source). 3. Select button 4 on the Calibrator (refer to Figure 8.6.4). 4. Call up the corresponding I/O Block Configuration screen and set it to MANUAL mode. 5. Set the Rosemount 262 Field Calibrator for 4.000 mA output. 6. Cursor to the Calibrate field and enter the following using NEXT OPTION: Cal Low. 7. Enter the following in the Calibrate field using NEXT OPTION: Cal High. 8. Set the Rosemount 262 Field Calibrator for 20.000 mA output. 9. Press Enter. The FIM will go through an internal calibration process. NOTE: Check calibration, if desired, using the preceding procedure. If calibration is outside of desired limits, repeat the procedure until the calibration is within desired limits. 10. Replace the field wiring and return the I/O block mode to AUTO. RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points SV: 8-6-6 RS3: Calibration Calibrating Multipoint Analog I/O (MAIO) Output and Input Points RS3t Service Manual Chapter 9: Maintenance Section 1: RS3: Maintenance Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-1 Cleaning Tape Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Floppy Disk Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Trackball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Console Fan Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Command Console Fan Filter ...................................... Cleaning Cabinet Filters and Screens .................................. Cabinet Door Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet Fan Screen .............................................. ControlFile Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI Card Cage, HIA, SCI, and SRU Fan Filter ........................ Cleaning Cabinet Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Active Hardware Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Glare Filter on a Command Console CRT . . . . . . . . . . . . . . . . . . . . Degaussing a Command Console CRT ............................. Console Diagnostic Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Off-Line Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlFile Power Regulator Card .................................. ControlFile Power Regulator Card Adjustment . . . . . . . . . . . . . . . . . . . . . . . . Operator Interface (OI) Power Regulator Card ....................... System Power Supply Units ....................................... Checking the AC/DC Power Supply Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the AC/DC Power Supply Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Backup Cards in Redundant Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Redundant Coordinator Processor Cards . . . . . . . . . . . . . . . . . . . . . Checking Redundant Controller Processor Cards . . . . . . . . . . . . . . . . . . . . . . . Removing and Installing Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan (System Power Supply Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-4 9-1-4 9-1-5 9-1-6 9-1-6 9-1-8 9-1-9 9-1-9 9-1-9 9-1-10 9-1-11 9-1-12 9-1-13 9-1-14 9-1-14 9-1-15 9-1-16 9-1-17 9-1-18 9-1-19 9-1-19 9-1-21 9-1-24 9-1-26 9-1-27 9-1-28 9-1-29 9-1-29 9-1-30 9-1-31 9-1-32 9-1-32 9-1-32 Contents SV: ii Section 2: Section 3: RS3: Maintenance Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-1 AC/DC Power Supply Battery and Charger Replacement . . . . . . . . . . . . . . . . . . . OI NV RAM Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Command and Basic Command Console Parts Replacement . . . . . . . . . . . . . . . Command Console Hard Disk Drive Removal ........................ Command Console Keyboard, Tape, or Floppy Disk Removal . . . . . . . . . . . FlexTerm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MultiLoop and Single-Strategy FlexTerm Replacement ................ Contact FlexTerm Replacement .................................... 9-2-2 9-2-4 9-2-5 9-2-6 9-2-9 9-2-11 9-2-11 9-2-13 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3-1 Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fiber Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3-1 9-3-2 9-3-2 9-3-3 9-3-3 Contents SV: iii List of Figures Figure RS3: Maintenance Page 9.1.1. Command Console Fan Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-7 9.1.2. Cabinet Filters and Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-8 9.1.3. Command Console CRT Degaussing and Filter Cleaning . . . . . . . . . . . 9-1-15 9.1.4. ControlFile Power Regulator Voltage and Current Checks . . . . . . . . . . 9-1-19 9.1.5. ControlFile Power Regulator Card Test Points . . . . . . . . . . . . . . . . . . . . 9-1-21 9.1.6. Power Regulator Card Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . 9-1-22 9.1.7. Console Power Regulator Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . 9-1-25 9.1.8. Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-26 9.1.9. Power Supply BATT Switch and Indicators . . . . . . . . . . . . . . . . . . . . . . . 9-1-27 9.1.10. ControlFile Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-30 9.2.1. Battery and Battery Charger Replacement . . . . . . . . . . . . . . . . . . . . . . . 9-2-2 9.2.2. Battery Charger Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-3 9.2.3. Basic Command Console and Command Console Card Cage Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-5 9.2.4. Command Console Rear View (Back Cover Open) . . . . . . . . . . . . . . . . 9-2-6 9.2.5. Card Cage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-7 9.2.6. Hard Disk Drive (Winchester) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-8 9.2.7. Keyboard and Tape/Disk Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-9 9.2.8. Keyboard Interface Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-10 9.2.9. Side Panel Removal Screw Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-11 9.2.10. MultiLoop FlexTerm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2-12 9.2.11. 9-2-13 Contact FlexTerm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents SV: iv List of Tables Table RS3: Maintenance Page 9.1.1. Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-2 9.1.2. Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-3 Contents SV: 9-1-1 Section 1: Scheduled Maintenance This section covers scheduled maintenance procedures for RS3 components. Periodic inspections, and adherence to the maintenance schedule, help to avoid system failures. Procedures in the Scheduled Maintenance Table are described in detail in this section. D D Cleaning — Tape drives — Floppy disk drives — Trackball — Filters — CRT — Cards Checking — LEDs — Calibration — Voltages — Batteries — Redundancy — Fans (System Power Supply Units) Scheduled maintenance procedures are tasks that must be performed periodically to keep the system hardware in reliable working condition. Table 9.1.1 gives the scheduled maintenance for parts of the system. RS3: Maintenance Scheduled Maintenance SV: 9-1-2 Table 9.1.1. Scheduled Maintenance Procedures Item Frequency Cleaning Tape Drives Magnetic Tape Drives Weekly Cleaning Console Fan Filters MiniConsole Cage Fan Filters MiniConsole Disk Drive Filters Basic Command Console Filters Command Console Cage Filters Weekly Cleaning Cabinet Filters Cabinet Door Filters ControlFile Fan Filters Cabinet Fan Screens Weekly Checking LEDs Disk Drives Consoles and ControlFiles Power Supplies Weekly Checking Active Hardware Alarms Hardware Alarm List Weekly Maintaining the Printer Change Ribbon As required Checking the AC/DC Power Supply Battery Battery 6 Months Replacing the AC/DC Power Supply Battery AC/DC Power Supplies Approximately every four years Replacing the System Power Supply Unit Cooling Fan Power Supply Cooling Fan 3.5 Years Maintaining the CRT Glare Filter on MiniConsole CRT CC and BCC CRT, Clean and Degauss 6 Months Running Off-Line Console Diagnostic Programs Off-Line Background Diagnostic Checks NOTE: This should be done only by authorized FRSI personnel. 6 Months Checking Calibration Analog Input Blocks (AIB) Analog Output Blocks (AOB) Multiplexer Input Blocks (MIB) 6 Months Checking Voltages ControlFile Power Regulator Console Power Regulator 6 Months Checking Backup Cards in Redundant Pairs Coordinator Processor Controllers 6 Months Cleaning Cards Consoles, Printer, ControlFiles & FlexTerms 12 Months or as required RS3: Maintenance Scheduled Maintenance SV: 9-1-3 Table 9.1.1 lists part numbers of filters used. Table 9.1.2. Replacement Filters Application Filter Part Name MiniConsole Card Cage G12918--0001 Fan Filter Replacement MiniConsole Floppy Disk Drive G12918--0002 Fan Filter Replacement Multitube EC Cabinet 1984--0359--0006 Fan Filter Replacement Command Console G12918--0002 Fan Filter Replacement Cabinet Door, Series I 1984--0359--0003 Filter Replacement, Door Cabinet Door, Series 2 1984--0359--0008 Cabinet Filter ControlFile 1984--0359--0001 Fan Filter Replacement Operator Interface (OI) Card Cage Highway Interface Adapter (HIA) Supervisory Computer Interface (SCI) System Resource Unit (SRU) 1984--0359--0002 Filter Replacement -- HIA, SCI, SRU Tower Electronics Cabinet 1984--0359--0007 Filter Replacement, Tower Door 7U Hanging Cabinet 10P55500011 Filter Replacement, Bottom of Cabinet Millennium Cabinet 55P0416X012 Filter Replacement, Door RS3: Maintenance Scheduled Maintenance SV: 9-1-4 Cleaning Tape Drives Magnetic tape drives should be cleaned once a week or after every 8 hours of tape operation. Clean the drive after 2 hours of operation with new tape cartridges. Use a 1984--2154--0001 Tape Drive Head Cleaner Kit. Additional supplies are available in the 1984--2154--0002 Tape Drive Head Cleaner Refill Kit. Follow the directions supplied with the kit. Cleaning Floppy Disk Drives Disk drives should be cleaned periodically or when excessive errors occur. Use a 1984--2891--0001 Floppy Drive Cleaner Kit for the 3.5-inch drives and a 1984--2891--0002 Floppy Drive Cleaner Kit for the 5.25-inch drives. RS3: Maintenance Scheduled Maintenance SV: 9-1-5 Cleaning the Trackball Most problems with a trackball can be cured by a thorough cleaning. Dirt accumulates around the ball itself and in the optical disk readouts inside the assembly. The trackball itself can be replaced without replacing the entire assembly. - To clean a trackball: Required tools: #1 Phillips screwdriver 1/16-inch Allen wrench Source of dry air under pressure (20 psi max) Denatured alcohol 1. The Trackball Assembly can be part of the Operator Keyboard Assembly or be free standing. a. Operator Keyboard Assembly: Unplug the keyboard cable from the keyboard interface card. Turn the keyboard assembly over and remove the four screws that hold the Trackball Assembly to the Operator Keyboard. b. Free-standing trackball: Unplug the trackball cable. Remove the four screws that hold the base in place. 2. Remove the two brackets that hold the black box containing the trackball. Push the black box out. This may require some force because the black box is glued to the assembly. 3. Unplug the black box from the trackball electronics. 4. Remove the black box top cover (four Allen screws). 5. Remove and clean the ball and the area around the hole in the cover. 6. Use dry air to blow dust and dirt out of the optical sensor wheels and sensors. 7. Clean the bearing that holds the ball tightly against the sensor wheels. 8. Reassemble the black box. 9. Connect the trackball electronics cable and install the box in the trackball assembly, being careful to center the ball in the hole in the keyboard before you tighten the brackets. 10. Replace the base or reinstall in the keyboard assembly. 11. Plug in the cable and test. If the trackball does not work, replace the black box (1984--1653--000x). RS3: Maintenance Scheduled Maintenance SV: 9-1-6 Cleaning Console Fan Filters Clean the console fan filters a minimum of once per week (more often in dusty environments) to allow for adequate cooling and to prevent failures from overheating. WARNING The fan blades are exposed during the fan cleaning procedure. To avoid injury, keep fingers away from the fan. - To clean a console filter: 1. Remove the filter. 2. Carefully vacuum the dust off the face of the filter. 3. If the filter is very dirty, clean it using clean water and a mild detergent. Dry the filter completely before reinstalling it in the console. 4. If there is a hole in a filter, replace it. Table 9.1.2 lists replacement part numbers. Command Console Fan Filter The Command Console fan filters are located on the bottom of the console. Figure 9.1.1 shows the location of the fan filters on a Command Console. - To clean a Command Console filter: WARNING The fan blades are exposed during the filter cleaning procedure. To avoid injury, keep fingers away from the fan. 1. Remove the filters by sliding them out towards the side of the console. 2. Carefully vacuum the dust from the face of the filter. 3. If the filters are very dirty, clean them using clean water and a mild detergent. Dry the filters completely before reinstalling them in the console. 4. If there is a hole in a filter, replace it. Table 9.1.2 lists replacement part numbers. RS3: Maintenance Scheduled Maintenance SV: 9-1-7 WARNING Fan blades are exposed when fan filter is removed. Keep fingers away. Slide filters out toward the side of the console. Console Fan Filters Figure 9.1.1. Command Console Fan Filter Removal RS3: Maintenance Scheduled Maintenance SV: 9-1-8 Cleaning Cabinet Filters and Screens Clean the cabinet filters at least once per week, and more often in a dusty environment. This allows adequate cooling to prevent equipment failures due to overheating. Figure 9.1.2 shows the location of the cabinet filters and cabinet fan screen. Cabinet Fan Screen ControlFile Fan Filter Loosen wing nuts and slide bracket up OI Card Cage Filter Cabinet door filters Figure 9.1.2. Cabinet Filters and Screen RS3: Maintenance Scheduled Maintenance SV: 9-1-9 Cabinet Door Filter - To clean the cabinet door filter: 1. Remove the cabinet door filter by loosening the wing nuts and sliding the bracket up. 2. Carefully vacuum the dust from the face of the filter. 3. If the filters are very dirty, wash them with a mild detergent and rinse with clean water. Dry the filters completely before reinstalling them. 4. If there is a hole in a filter, replace it. Table 9.1.2 lists replacement part numbers. Cabinet Fan Screen - To clean the cabinet fan screens: 1. Check the fan cover screens above and below the cabinet cooling fans for accumulated dust and contaminants. 2. Use a vacuum cleaner to remove the accumulated dust. 3. If the screens are very dirty, remove them, wash them with a mild detergent, and rinse with clean water. Dry the screens completely before reinstalling them. ControlFile Fan Filter - To clean the ControlFile fan filters: 1. Remove the ControlFile fan filters by removing the two screws on either side of the filter. 2. Carefully vacuum the dust from the face of the filter. 3. If the filters are very dirty, wash them with a mild detergent and rinse with clean water. Dry the filters completely before reinstalling them. 4. If there is a hole in a filter, replace it. Table 9.1.2 lists replacement part numbers. RS3: Maintenance Scheduled Maintenance SV: 9-1-10 OI Card Cage, HIA, SCI, and SRU Fan Filter - To clean the OI Card Cage fan filter: 1. Remove the filter by removing the two screws on either side of the filter. 2. Carefully vacuum the dust from the face of the filter. 3. If the filter is very dirty, wash it with a mild detergent and rinse with clean water. Dry the filter completely before reinstalling it. 4. If there is a hole in a filter, replace it. Table 9.1.2 lists replacement part numbers. RS3: Maintenance Scheduled Maintenance SV: 9-1-11 Cleaning Cabinet Surfaces Clean the cabinet/enclosure surfaces and the work surfaces with a mild cleaner, such as a dish soap or other cleaner (e.g., “Simple Green”) and clean tap water. Follow the manufacturer’s directions for proper use. Use a damp cloth or sponge to apply the cleaner to loosen the dirt and to remove the mixture of cleaner and residual dirt. Use a nylon or natural bristle brush on the more difficult areas. This may not remove all stains. Do not use a harsh cleaner or an abrasive brush, as this may reduce the protection offered by painted or coated surfaces. RS3: Maintenance Scheduled Maintenance SV: 9-1-12 Checking LEDs LEDs are used on the front of power supplies, the faceplates of cards, and on disk drives to indicate status. No red LEDs should be lighted. Find and repair the cause of any lighted red LEDs before proceeding with other scheduled maintenance procedures. RS3: Maintenance Scheduled Maintenance SV: 9-1-13 Checking Active Hardware Alarms Each Active Hardware Alarm must be periodically checked and verified to make sure that it is an active alarm. The problem should be corrected if possible and any inactive alarms deleted. If the alarms are no longer active, they can be cleared off the Active Alarm list. Alarms are cleared off the Active Alarm list by using the console Configuror’s key, cursoring to each individual alarm, and pressing the “C” key. (Not CTL--C.) It is possible for the system to create hardware alarms and not clear them. For example, if a “No Bubble Board Present” alarm is created by a Coordinator Processor and that Coordinator Processor is then restarted, the “No Bubble Board Present” alarm will not be cleared from the Active Hardware Alarm list at the console because the Coordinator Processor memory of the alarm was cleared with the Coordinator Processor restart. CAUTION Make certain that all alarms are carefully checked and that active alarms are not deleted. Check the Active Hardware Alarm list of each console for alarms and investigate any active alarms showing. If they are true active Hardware Alarms they should be dealt with in an appropriate manner. Refer to the Alarm Messages Manual (AL) for a summary and description of alarm messages. RS3: Maintenance Scheduled Maintenance SV: 9-1-14 Maintaining the CRT Periodically, CRT glare filters must be cleaned and the CRT screen must be degaussed. Cleaning Glare Filter on a Command Console CRT Clean glare filter on a Command Console to remove accumulated dust and to prevent blurring of the screen image. Figure 9.1.3 shows the location of the power and signal cables on the Command Console. - To clean a Command Console CRT: 1. Turn off power to console on the rear panel of the Command Console. 2. Remove AC power cable, three coaxial signal cables, and the green ground wire on the rear of the CRT. WARNING Prevent the CRT from sliding off the table, hold the CRT pan so that it does not tilt while you are removing the CRT screws. 3. Remove six screws under the CRT pan holding the CRT in place. Remove the CRT from the console. 4. Clean the CRT filter and screen using a soft cloth and mild soap and water. RS3: Maintenance Scheduled Maintenance SV: 9-1-15 Degaussing a Command Console CRT Degauss CRTs periodically to remove stray magnetic fields that build up and cause loss of color convergencies and blurred colors. Figure 9.1.3 shows the location of the degauss button on the CRT monitor. - To degauss a Command Console CRT: NOTE: The degauss button is accessible on some consoles through a hole in the side of the CRT cover. 1. Remove the six screws holding the CRT cover in place and lift the cover off. 2. Press and hold the degauss button on the top of the CRT frame for 10 seconds. The screen images are distorted while the degauss button is held down. Degauss Button Remove Power And Signal Cables Console Power Switches Figure 9.1.3. Command Console CRT Degaussing and Filter Cleaning RS3: Maintenance Scheduled Maintenance SV: 9-1-16 Console Diagnostic Programs Run Console Online and Off-line Diagnostic programs as a routine maintenance item. This will help identify possible problem areas before they affect the operation of the console. The Off-line Diagnostics for the MiniConsole and the Command Console are loaded from a special console program floppy disk. The Command Console Off-line Diagnostics are loaded from a special tape. CAUTION Running off line diagnostic tests removes the console from active process operation. Alarms, trending and the process operation are not active while the off line tests are being run. RS3: Maintenance Scheduled Maintenance SV: 9-1-17 Running Off-Line Diagnostics NOTE: Only FRSI personnel should run off-line diagnostic programs. - To run the off-line diagnostics: 1. For a Command Console, insert the appropriate Off-Line Diagnostics tape in the console tape drive, turn the console power off for 30 seconds and then back on. Hold down the “Hardware Alarm” button during the power up diagnostics until the console indicates it is “Booting From Streaming Tape”. This boots the console and brings up the Off-Line Diagnostics Menu. 2. For a MiniConsole or Basic Command Console, insert the appropriate Off-line Diagnostics disk in either disk drive, turn off the console power for 30 seconds and then back on. This boots the console and brings up the Off-line Diagnostics Menu. 3. Check the Power Up Diagnostic screen for any faults. 4. Run the following tests: — Processor RAM Test — Character/Att Test — Floppy Disk Exerciser (MiniConsole and Basic Command Console) — Tape Exerciser (Command Console) — Winchester Disk Exerciser (Command Console) CAUTION If you are running the hard disk tests, ensure that a “Full Image Backup to Tape” is done before the test so the console configuration can be reloaded at the conclusion of testing. RS3: Maintenance — Processor ROM Test — All Keyboard Tests Scheduled Maintenance SV: 9-1-18 Checking Calibration The 4-20 mA signal used by Analog Input Blocks (AIB) and Analog Output Blocks (AOB) of MultiLoop cards (MLC) and constants for Multiplexer Input Blocks (MIB) are referenced to calibration information stored in ControlFile nonvolatile memory. This reference signal is calibrated if a check for accuracy is made. The 4-20 mA signal used by Analog Input Blocks (AIB) and Analog Output Blocks (AOB) of Field Interface cards (FICs) and Field Interface modules (FIMs) are referenced to calibration information stored in the FIC or FIM on-board nonvolatile memory. This reference signal is calibrated if a check for accuracy is made. For procedures, see Chapter 8, Calibration. RS3: Maintenance Scheduled Maintenance SV: 9-1-19 Checking Voltages Check the voltages in each ControlFile and Console. ControlFile Power Regulator Card Check voltages on the ControlFile to assure proper operation. Figure 9.1.4 shows the ControlFile test point locations on the top of the ControlFile. Power Regulator Card Test Points Green White Brown Blue Yellow Red 12 I 5I Gnd --12 +5 +12 Controller Test Points Brown Yellow GND +5 Top View of ControlFile Multi and Single Also Included Nonvolatile Memory Card Test Points Brown Yellow Red Blue Red --12 +12 GND +5 +12 Figure 9.1.4. ControlFile Power Regulator Voltage and Current Checks RS3: Maintenance Scheduled Maintenance SV: 9-1-20 - To check ControlFile voltages: 1. Pull the ControlFile out on its rails. 2. Open the ControlFile door and remove the shipping screw (if present) on the upper left corner of the ControlFile. 3. Use a 4 1/2 digit digital voltmeter (19.999 volt range capability) to check the voltages. NOTE: If any of the following voltage checks do not appear to be correct, see the calibration procedure later in this section. a. Current Share, +12 Volts (Redundant Power Regulators only). Measure the voltage between the green test points on both Power Regulator cards in the ControlFile. The voltage should be less than 100 millivolts (0.100 volt). The polarity does not matter. b. Current Share, +5 Volts (Redundant Power Regulators only). Measure the voltage between the white test points on both Power Regulator cards in the ControlFile. The voltage should be less than 200 millivolts (0.200 volt). The polarity does not matter. c. Voltage Check (ControlFiles with test points on Controllers). For 5 Volts: Measure the voltage between the yellow (+) and brown (--) test points on the Controller Processor card in the farthest right slot. The voltage should measure between +4.95 and +5.05 volts. For +12 Volts: Measure the voltage between the red (+) and brown (--) test points on the bubble card. The voltage should measure between +11.95 and +12.10 volts. d. Voltage Check (ControlFiles without test points on Controllers). For +5 Volts: Measure the voltage between the yellow (+) and brown (--) test points on the Power Regulator card. The voltage should measure between +5.15 and +5.25 volts. For +12 Volts: Measure the voltage between the red (+) and brown (--) test points on the Power Regulator card. The voltage should measure between +12.10 and +12.20 volts. RS3: Maintenance Scheduled Maintenance SV: 9-1-21 ControlFile Power Regulator Card Adjustment NOTE: Voltage adjustments should be made only if the voltage checks indicate they need to be adjusted. These are factory adjustments and should not require periodic changing. Make the series of voltage adjustments on the ControlFile to ensure proper voltage and current balance between the two redundant Power Regulators in the ControlFile. The voltage test points to use are on the top of the ControlFile. The ControlFile is on rails and can be pulled out. For explanations of the voltages, see the circuit description of the ControlFile Power Regulator card in Chapter 4, “ControlFiles”. Figure 9.1.5 shows the Power Regulator card test points. Figure 9.1.5 shows the voltage adjustment locations on the Power Regulator card. CAUTION Voltage checks must be made with all ControlFile card switches in the DISABLE position. Power Regulator Test Points Green White Brown Blue Yellow Red 12 I 5I Gnd --12 +5 +12 NOTE: Some Cards May Not Have Test Points Controller Test Points Brown Yellow TOP VIEW OF ControlFile Gnd +5 Multi and Single Also Include Blue Red --12 +12 Bubble Card Test Points Brown Yellow Red Gnd +5 +12 Figure 9.1.5. ControlFile Power Regulator Card Test Points RS3: Maintenance Scheduled Maintenance SV: 9-1-22 RV 1 5 Volt Adjust RV 2 12 Volt Adjust CAUTION Adjust only RV1 and RV2 on this card. Figure 9.1.6. Power Regulator Card Voltage Adjustments - To adjust a ControlFile power regulator card: 1. Open the ControlFile door and remove the shipping screw on the upper left corner of the ControlFile. 2. Check that adequate cable length is available on the rear of the ControlFile and pull it out on the rails. 3. Remove the right hand Power Regulator card from the ControlFile if redundant Power Regulators are installed in the ControlFile. If a single regulator is used, it is easier to adjust if it is in the left slot. Use a short insulated screwdriver for all adjustments. To make adjustment easier you may also remove the redundant Coordinator Processor or if a nonredundant Coordinator Processor card is used, move it to the right slot. NOTE: These voltage checks require a 4 1/2 digit digital voltmeter. (19.999 volt range capability.) a. ControlFiles with test points on Controller Processor cards: +5 Volt Adjustment: Measure the voltage between the yellow (+) and brown (--) test points on the Controller in the farthest right slot. Adjust the voltage to measure exactly +5.000 volts by turning RV 1. +12 Volt Adjustment: Measure the voltage between the red (+) and brown (--) test points on the Nonvolatile Memory card. Adjust the voltage to measure exactly +12.000 volts by turning RV 2. RS3: Maintenance Scheduled Maintenance SV: 9-1-23 b. ControlFiles without test points on Controller Processor cards: +12 Volt Adjustment: Measure the voltage between the red (+) and brown (--) test points on the Power Regulator card. Adjust the voltage to measure exactly +12.100 volts by turning RV 2. 4. If a single Power Regulator is used in the ControlFile, the procedure is complete. If redundant Power Regulators are used, go to step 5. 5. Remove the left Power Regulator card and insert the redundant Power Regulator card in the left slot and repeat steps a or b above, as appropriate. 6. After both Power Regulators card have been adjusted, insert the second Power Regulator card into the right slot and make the following checks. a. Current Share, +12 Volts. (redundant Power Regulators only) Measure the voltage between the green test points on both Power Regulator cards in the ControlFile. The voltage should be less than 100 millivolts (0.100 volt). The polarity does not matter. b. Current Share, +5 Volts. (redundant Power Regulators only) Measure the voltage between the white test points on both Power Regulator cards in the ControlFile. The voltage should be less than 200 millivolts (0.200 volt). The polarity does not matter. c. Check the last (farthest right) Controller Processor card in the ControlFile to make sure the voltage is between 4.95 and 5.05 VDC. NOTE: If any of the preceding voltage checks do not appear correct, repeat the procedure. If they are still not correct, contact your local FRSI Service Representative. RS3: Maintenance Scheduled Maintenance SV: 9-1-24 Operator Interface (OI) Power Regulator Card Make voltage checks on each MiniConsole and Command Console Power Regulator card to ensure proper operation. The Command Console will have one of the two power regulators as shown in Figure 9.1.7 . Determine which is installed in the console and make the appropriate voltage checks. The console does not need to be powered down for these voltage checks. The voltage checks require a 4-1/2 digit digital voltmeter (19.999 volt range capability). Open a MiniConsole by loosening the captive screws on the disk drive and pulling the MiniConsole out 2 to 3 inches (5 to 8 cm). Open the front casting by loosening the two front casting captive screws. Open a Command Console by removing the four screws securing the rear door of the console. RS3: Maintenance Scheduled Maintenance SV: 9-1-25 G NOTE: If any console voltage checks do not appear correct, contact your local FRSI Service Representative. G R R R R R R Y Y Y Y Y Y Y Y Measure between 5.100 and 5.200 Volts Measure between 5.100 and 5.200 Volts Measure between 12.100 and 12.200 Volts Measure between 12.100 and 12.200 Volts Console Power Regulator without Connector Console Power Regulator with Connector Figure 9.1.7. Console Power Regulator Voltage Checks RS3: Maintenance Scheduled Maintenance SV: 9-1-26 System Power Supply Units Make voltage checks on each power supply module to ensure proper operation. Each power supply module converts AC line voltage to the DC voltage required by the equipment and field instruments. The power supply module output is rated at 1200 watts. The switching power supplies have universal AC inputs with power factor correction and can operate over an input range of 85--264 VAC, 47--63 Hz without reconfiguration. However, this supply voltage will be passed through auxiliary output, so AC voltage ranges for auxiliary devices (cabinet fans) must be properly defined. The power supply module outputs are provided with overvoltage, overcurrent, and short circuit protection. A pair of isolated test jacks on the front of each power supply module enable monitoring of output current (see Figure 9.1.8). Each power supply module has two front-mounted LEDs: D D The amber LED indicates that the power supply module’s AC input is energized. The green LED indicates that the DC output voltage is within tolerances. FAN LED Indicators and Current Monitor Test Jacks DC AC -+ 1 VDC = 100% LOAD I O P O W E R L O C K Figure 9.1.8. Power Supply Module RS3: Maintenance Scheduled Maintenance SV: 9-1-27 Checking the AC/DC Power Supply Battery In order to check the AC/DC power supply battery, the Power Supply NORM indicator (green LED) must be on and the equipment must be running for at least five minutes. A timer prevents battery testing before five minutes after power is applied or within five minutes of a previous battery test. - To test the battery: 1. Press the BATT TEST pushbutton (Figure 9.1.9) once. 2. The Power Supply NORM indicator (green LED) will go off for approximately 5 seconds and then come back on. 3. If the Power Supply FAULT indicator (red LED) comes on, see Chapter 9 for troubleshooting guidance. OUTPUT CURRENT 30 TEST BATT BATT TEST Pushbutton FAULT NORM PS 3 FAULT NORM and FAULT Indicators BATT ON BATT FAULT OFF PS FAULT LINE RTN NEUT AC IN POS GND PS OUTPUT Figure 9.1.9. Power Supply BATT Switch and Indicators RS3: Maintenance Scheduled Maintenance SV: 9-1-28 Replacing the AC/DC Power Supply Battery The AC/DC power supply batteries should be replaced periodically to maintain adequate backup power in the event of an AC power failure. The replacement time of the batteries is dependent on the amount of use the batteries receive and the ambient temperature. In general. batteries in ambient temperatures under 30_ C (86_ F) should be replaced every three years. The procedure for removal and replacement of power supply batteries is covered in the Parts Replacement section of this chapter. NOTE: Always replace batteries in pairs. Do not mix batteries from different manufacturers. Chapter 1 of this manual gives a hardware description of the AC/DC power supply and the battery charger board. RS3: Maintenance Scheduled Maintenance SV: 9-1-29 Checking Backup Cards in Redundant Pairs When redundant Coordinator Processor and Controller Processor cards are used, the backup cards should be checked for proper operation to assure complete system integrity. This test is done using a Configuror’s key on any console that owns the particular node. NOTE: Switching to the backup cards in the ControlFile will not affect process operation. However it is recommended that these tests be run off line to allow troubleshooting when necessary. Checking Redundant Coordinator Processor Cards - To enable redundant Coordinator Processor cards: 1. Make sure there are no Alarm indications on the redundant Coordinator Processor card. If the word “Alarm” is next to the Boot Level indication, you must clear a problem on the redundant Coordinator processor card before proceeding with the test. 2. Bring the cursor down to the redundant Coordinator Processor indication on the ControlFile Status screen (see Figure 9.1.10). The cursor will go only to the redundant unit. 3. Press the ENTER button and observe that within a few seconds the redundant Coordinator Processor card takes over as primary. The changeover will be indicated by the Program Level, Links, and Idle Time information moving to the other card. A “CP Switch Complete” alarm will also be generated. If the backup card fails for any reason, the original card will take over and an alarm will be generated indicating the faulty card. 4. Allow the new card to run for several minutes to assure proper operation. If you choose, the card that was switched in can be left as primary CP. This will not affect system operation. 5. Repeat steps 1 through 4 for all ControlFiles with redundant Coordinator Processor cards. RS3: Maintenance Scheduled Maintenance SV: 9-1-30 Checking Redundant Controller Processor Cards - To enable redundant Controller Processor cards: 1. Make sure there are no Alarm indications on the redundant Controller card. If the word “Alarm” is on the ControlFile Status screen, you must clear a problem with the redundant card before the test can continue. 2. The primary Controller Processor will show all values. The redundant processor shows which card is primary (“A” in Figure 9.1.10). Cursor to the primary indication (“A”). 3. Press ENTER and observe that the redundant card takes over as primary CP within a few seconds. The changeover will be indicated by operating data moving to the new card. A “Cont switch Complete” alarm will be generated. If the backup card fails for any reason, the original card will take over and an alarm will be generated indicating the faulty card. 4. Allow the new card to run for several minutes to assure proper operation. If you choose, the card that was switched in can be left as primary CP. This will not affect system operation. 5. Repeat steps 1 through 4 for all redundant Controller Processor cards. CONTROL FILE STATUS 07-Aug-98 15:34:12 Node Address >1 File Status >Stdby Batch CP Batch Config NVM 128 K Left CP: Boot 4.03 Prgm P1.09 Avail Links 39 Idle Time 45. % Right CP: Boot 4.03 Left Program NVM Free 32. % BRAM V1.16 Soft Count 0 Additional Images: 1. MPC2+ Config NVM Free 328 K +--------------- A --- B --- C --- D --- E --- F --- G --- H Alarm MPC+ 6.05 P1.11 95. % 96. % 76 4600 Alarm MPC+ 6.05 P1.11 47. % 54. % 69 4554 MPC+ 6.05 P1.11 86. % 98. % 77 4554 PLC+ 6.05 P1.11 97. % 99. % 77 4600 ®Norm ®no ®no ®Norm ®no ®no ®Norm ®no ®no >Stdby ®no ®no 1_7_7 1_7_7 1_7_7 1_7_6 SC Time Out ÞNone ÞNone ÞNone ÞNone Scan time NV Mem Used Þ1. S 8 K Þ1. S 32 K Þ.25 S 8 K Þ1. S 8 K Control Type Boot Rev Prgm Rev Idle Time Free Space Avail Links Avl Trnd Spc Primary Status Alarm Inhib Start Cal Start Cal Jumper Code Figure 9.1.10. ControlFile Status Screen RS3: Maintenance Scheduled Maintenance SV: 9-1-31 Removing and Installing Cards You must follow these precautions and procedures when removing or inserting cards in the system. Observe these precautions and instructions when working on the system. 1 D D D D Use a grounded wrist strap with a built-in one megohm resistor for your safety and to prevent damage to static sensitive circuits. The resistor allows static electricity to drain to ground while isolating you from direct ground. Before removing AC and DC power from the system, move all Nonvolatile Memory card ENABLE/DISABLE switches to the DISABLE position. Before removing or inserting any card (except a PeerWay buffer card) in a ControlFile, first disable the Nonvolatile Memory card, then disable the secondary Coordinator Processor card, and then disable the primary Coordinator Processor card by placing the ENABLE/DISABLE switches to the DISABLE position. Always power down consoles before removing or installing cards. NOTE: The Disk Shutdown (DS) command should always be performed before powering down the console. This will purge the cache and prevent possible loss of data. D Check the jumper positions when you replace a card. D Ensure that cards are seated properly. D D D D RS3: Maintenance — Place your right thumb on the upper plastic card extractor lever and place your left thumb on the lower extractor. — Push evenly and firmly with both thumbs at the same time. You should feel the card seat. All circuit cards must be in antistatic bags when outside their card cage. Use approved antistatic bags when shipping or storing cards. Never handle circuit cards by the edge connectors. Small amounts of oil from your skin can contaminate the edge connectors, causing problems with intermittent contacts. Use only approved nonstatic brushes to clean edge connectors. Never use erasers, abrasive materials, or nylon brushes. Abrasives can remove the gold flash, and other materials can cause static electricity damage to onboard components. Follow the instructions in “Cleaning Cards” in this section. When powering up the ControlFile, first enable the Nonvolatile Memory card, then enable the primary Coordinator Processor card, and then enable the secondary Coordinator Processor card. Scheduled Maintenance SV: 9-1-32 Cleaning Cards Cards should be removed and cleaned once a year (more often in installations where conductive dust is present). The cards must be removed and cleaned in an antistatic work area. Use an antistatic mat on the work surface and an antistatic wrist strap. Clean cards with a static-protected air hose or vacuum cleaner. - To remove dust from cards: 1. Use an air hose to blow the dust off the cards and assemblies. Use very dry air or an ionizing nozzle on the air hose to prevent static damage to the cards. Air pressure should be limited to 2.1 Kg/cm2 (30 psi). or 2. Use a vacuum cleaner. We recommend use of a dust attachment with a wire wrapped around the brush bristles. Connect the wire to ground through a 1 megohm resistor to eliminate static buildup on the brush. - To clean edge connectors: CAUTION Do not use a rubber eraser to clean edge connectors. A rubber eraser wears away the thin gold coating on the connector and will then allow the contacts to corrode. 1. Use a “RUSH BRUSH” or similarly designed edge connector brush to remove oxidation and contaminants from the gold coated edge connectors. 2. To remove contaminants, wipe connector contacts with a soft tissue wetted with denatured alcohol. Storing Cards Cards must be stored in a clean area, free of corrosives. Always store cards in an approved antistatic bag. Cooling Fan (System Power Supply Units) The only regular maintenance required for the System Power Supply Unit is replacing the cooling fans on the power supply modules. The recommended maintenance interval for replacing the fan is 3.5 years (42 months). See SV:NO TAG for detailed information on fan replacement. RS3: Maintenance Scheduled Maintenance SV: 9-2-1 Section 2: Parts Replacement This section gives details on how to replace parts of the RS3. Procedures are not given for all parts in the system, but for those that may be complicated. The person performing the maintenance should have attended an RS3 maintenance class. Proper procedures (as outlined below) must always be followed when removing or installing modules in the system. It is also assumed that the technician working on the system is familiar with the plant process operations and the consequences of any actions taken. Observe the following precautions and instructions while working on the RS3: Parts of devices that are listed as replacement parts are permitted to be replaced in the field with the stated replacement part as designated in the user documentation. Any part of a device that is not listed as a replacement part is not to be replaced in the field, but must be returned to the factory for repair. D Use a grounded wrist strap with a built in one megohm resistor for your safety and to prevent damage to static sensitive circuits. The resistor allows static electricity to drain to ground and still isolates you from direct ground. D Always first disable the Nonvolatile Memory and then the primary and secondary Coordinator Processor cards before removing or inserting cards in the ControlFile (with the exception of the PeerWay Buffer cards). D Always power down consoles before removing or installing console cards. D D D D NOTE: The Disk Shutdown (DS) command should always be performed before powering down the console. This will purge the cache and prevent possible loss of data. Disable the Nonvolatile Memory card before removing AC and DC power. Any circuit card assemblies that are removed from the system and stored or transported must be put into antistatic bags. Never handle circuit card assemblies by the edge connectors. Small amounts of oil from your skin can contaminate the edge connectors and cause intermittent contacts and problems with the system. When powering up the ControlFile, first enable the Nonvolatile Memory card and then enable the primary and secondary Coordinator Processor cards. NOTE: The numbers circled in the figures of this section refer to the steps in the procedures. RS3: Maintenance Parts Replacement SV: 9-2-2 AC/DC Power Supply Battery and Charger Replacement It may be possible to turn off one AC/DC Power Supply for maintenance purposes and not affect the rest of the system operation if the remaining supplies have sufficient capacity to carry the current. This can be determined by checking the current meter on each remaining supply. CAUTION If the complete system is to be shut down, the switches on the Nonvolatile Memory cards must be switched off before turning off the AC and battery power. Figure 9.2.1 shows the AC/DC Power Supply. Battery Charger Board AC/DC Power Supply Battery Tray Screws AC Breaker AC Entrance Panel Figure 9.2.1. Battery and Battery Charger Replacement RS3: Maintenance Parts Replacement SV: 9-2-3 - To access the power supply and batteries: 1. Turn off the battery switch on the AC/DC Power Supply. 2. Turn off the breaker on AC entrance panel to the AC/DC Power Supply. WARNING To prevent accidental injury, make certain you have turned off the correct circuit breaker. The amber light on the front of the power supply should be off. 3. Remove all cables to the AC/DC Supply. 4. Remove the bracket in front of the supply holding it in place. WARNING The AC/DC Power Supply weighs 70 pounds (32 kg). At least two persons should remove the supply from the cabinet to prevent injury. 5. Remove the supply from the cabinet. 6. Remove the cover over the batteries and open the battery charger compartment access door. 7. The batteries or battery charger can be removed. NOTE: If a replacement battery or battery charger board is not available, the AC/DC Power Supply can be reinstalled without them and will supply 30 volts DC to the system as long as AC voltage is available. 8. When replacing the battery charger board, make sure the cables are installed correctly. See Figure 9.2.2. Green Wire On Cable Goes Here White Dot On Cable Goes Here Two Wire Cable J0 J192 Figure 9.2.2. Battery Charger Cable Connections RS3: Maintenance Parts Replacement SV: 9-2-4 OI NV RAM Battery Replacement If either battery is low, the corresponding red LED lights and an alarm is generated. Both batteries should be replaced as soon as practical. See the write-up on the NV RAM card for the battery part number. NOTE: Replace only one battery at a time so that the other may keep the RAM refreshed. - To replace the batteries: CAUTION Use a grounded wrist strap with a built-in one megohm resistor for your safety and to prevent damage to static sensitive circuits (such as the RAM). 1. Power down the card cage and remove the OI NV RAM card. 2. Disconnect the battery by setting the jumper (HD1 or HD2) to “OFF”. 3. Replace the battery and reconnect it by setting the jumper to “ON”. Mark the date on the Battery Date Code label. 4. Repeat for the other battery. 5. Restore the card to the cage and power up the cage. RS3: Maintenance Parts Replacement SV: 9-2-5 Command and Basic Command Console Parts Replacement Figure 9.2.3 shows the cable connections on the rear of the Command Console. CAUTION To prevent damage to components, only the Printer and PeerWay connections may be changed with power to the console turned on. Keyboard Cable PeerWay A Winchester and Tape Drive on Command Console or Disk Drive on Basic Command Console Console Alarm Modules Printer PeerWAy B 30 Volt Power (A Bus) Color CRT Redundant 30 Volt Power (Optional B Bus) Fan Power Disk Drive Power Figure 9.2.3. Basic Command Console and Command Console Card Cage Cable Connections RS3: Maintenance Parts Replacement SV: 9-2-6 Command Console Hard Disk Drive Removal - To remove the Command Console hard disk drive: 1. Turn off both AC and DC power switches on Command Console. 2. If optional Power Supply is present, turn off battery and AC power. WARNING Disconnect the AC plugs in the support column to prevent shock when disconnecting the AC power cables on the supply. 3. Remove optional Power Supply by removing power cables and loosening captive screws holding the unit to the chassis. (See Figure 9.2.4.) 4. Loosen the four captive screws holding the card cage in place from the bottom of the chassis. (See Figure 9.2.4) Hard Disk Drive Optional Power Supply Card Cage Captive Screws (4) Accessible Through Holes in Underside of Housing Power Supply Captive Screws (4) Accessible Through Holes in Underside of Housing AC Plugs Figure 9.2.4. Command Console Rear View (Back Cover Open) 5. Carefully pull the card cage out and put it on a chair for support. See Figure 9.2.5. 6. Disconnect the power cables on the rear of the disk drive. 7. Remove the four screws holding the hard disk drive in place and pull drive out just enough to remove flat cable. RS3: Maintenance Parts Replacement SV: 9-2-7 CARD CAGE Figure 9.2.5. Card Cage Removal 8. When installing a new hard disk drive, verify that the jumpers are the same as indicated in Figure 9.2.6. CAUTION Make certain that ALL pins on the flat cable are connected properly to mating pins on the hard drive. It is possible to install the cable incorrectly and possibly damage the drive or SCSI Interface Card. 9. When reinstalling the card cage, make sure the CRT connector is seated properly, see Figure 9.2.6 . Carefully work the cables into the area in back of the card cage so you do not crimp the cables. RS3: Maintenance Parts Replacement SV: 9-2-8 1 RED TRACE ON CABLE GOES HERE WARNING USE EXTREME CARE WHEN CONNECTING 50 PIN CONNECTOR. ALL PINS MUST BE CONNECTED PROPERLY. CORRECT JUMPER POSITIONS 50 HARD DISK DRIVE POWER SCSI CONTROLLER POWER Figure 9.2.6. Hard Disk Drive (Winchester) RS3: Maintenance Parts Replacement SV: 9-2-9 Command Console Keyboard, Tape, or Floppy Disk Removal - To remove a Command Console keyboard, tape, or floppy disk: 1. Turn off power to Command Console. 2. Remove the nine screws holding keyboard bezel in place. 3. Remove screws holding the keyboard in place. Figure 9.2.7 shows the screws. Figure 9.2.8 shows the cable connections. NOTE: When removing the Configurer’s keyboard, you must disconnect the keyswitch cable from the keyboard interface, located under the Command Entry Keyboard. 4. When replacing disk drives see Chapter 3, Section 4 for jumper settings on the drive you have. TAPE/DISK AND LOOP CALLUP Remove Nine Bezel Screws COMMAND ENTRY KEYBOARD CONFIG. KEYBOARD TRACKBALL KEYBOARD ROTATING KEYBOARD See Note Figure 9.2.7. Keyboard and Tape/Disk Drive Removal RS3: Maintenance Parts Replacement SV: 9-2-10 Keyboard Shown Spread Out For Clarity Only LOOP CALLUP KEYBOARD J344 CONFIG. KEYBOARD 1984--1921--0001 KEYBOARD INTERFACE (SHOWN WITH PARTS FACING DOWN.) J335 TRACKBALL KEYBOARD J336 J333 J339 J338 J334 CABLE INSTALLED WITH 1/2 TWIST J337 CARD CAGE MOTHERBOARD ROTATING KEYBOARD COMMAND ENTRY KEYBOARD Figure 9.2.8. Keyboard Interface Cable Connections RS3: Maintenance Parts Replacement SV: 9-2-11 FlexTerm Replacement This portion of the section covers: D MultiLoop and Single-Strategy FlexTerm Replacement D Contact FlexTerm Replacement MultiLoop and Single-Strategy FlexTerm Replacement - To replace a MultiLoop or Single-Strategy FlexTerm: 1. Remove side panels from cabinet to gain access to rear of FlexTerm. There is normally a screw on the front and rear of the panel near the center. Remove the side by pushing it up from the bottom. See Figure 9.2.9. NOTE: Do not remove field wiring from the field termination card when replacing the FlexTerm. Side View Of Cabinet Side Panel Screw Locations, Inside Cabinet Push Up Along This Edge Figure 9.2.9. Side Panel Removal Screw Locations 2. Remove DC power cable and both flat cables from the FlexTerm. See Figure 9.2.10. You may find it necessary to remove the DC and flat cables of all FlexTerms in that cabinet in order to move the FlexTerm past the cables of the other FlexTerms. CAUTION Power off all field powered transmitters off before proceeding to prevent damage to components. RS3: Maintenance Parts Replacement SV: 9-2-12 3. Remove all Field Interface cards from the card cage. 4. Remove the tie wraps holding the field wiring to the side bracket of the FlexTerm card cage. 5. Remove screws holding field termination board in place. (Also remove screws holding recorder termination on left side of card cage if present.) Pull termination board from the socket. 6. Remove the six screws holding the motherboard to the side panels. This must be done from the back side of the FlexTerm. 7. Remove the FlexTerm motherboard by spreading the side panels slightly and pulling the left side out first. 3 2 5 3 Figure 9.2.10. MultiLoop FlexTerm Replacement RS3: Maintenance Parts Replacement SV: 9-2-13 Contact FlexTerm Replacement - To replace a Contact FlexTerm: 1. Remove the DC power connector and flat cables from the top and bottom on the FlexTerm. See Figure 9.2.11. WARNING To prevent injury or damage to components, all field power to the FlexTerm must be removed before attempting to remove a Contact FlexTerm. 1 DO NOT REMOVE THIS ROW OF SCREWS 5 4 3 2 1 Figure 9.2.11. Contact FlexTerm Replacement 2. Remove all Field Interface cards from the card cage. 3. Carefully cut the tiewraps holding the field wiring cables to the motherboard between the two field termination cards. NOTE: Do not remove field wiring from the field termination card when replacing the FlexTerm. 4. Loosen the two captive screws on both Contact field termination cards and pull the field termination cards out of the sockets. RS3: Maintenance Parts Replacement SV: 9-2-14 5. Remove the four screws holding the motherboard to the wire tray. 6. Remove the four screws holding the left side of the FlexTerm to the cabinet. 7. Holding the field termination cards out of the way, pull the FlexTerm out of the cabinet by pulling the left side out first. RS3: Maintenance Parts Replacement SV: 9-3-1 Section 3: Recommended Tools This section lists the tools recommended for servicing RS3 equipment. Hand Tools 1. Screwdrivers: a. Phillips, 10I minimum blade length, number 1 tip. For Analog Power Supply adjustment. b. Phillips, offset head. c. Common tip (flat), 14I minimum blade length. For removal of CPU Power Supply. 2. 1/4I drive socket set with sockets from 5/32I to 9/16I, ratchet, and extensions. Equivalent to Model B--80224 from: Marshall Claude Michael 9674 Telstar Ave. EL Monte, CA 91731 3. Tool Kit EZE--ZIP2 Catalog #E22ZTX from: Marshall Claude Michael 9674 Telstar Ave. EL Monte, CA 91731 Technitool #7715 from: Technitool 1--800--832--4866 RS3: Maintenance Recommended Tools SV: 9-3-2 Electronics 1. 3M Static Pad, Model 8501, FRSI P/N 7983--0039 2. 3M Portable Field Service Static Kit 3. 4 1/2 digit DVM Fluke Model 8060A with frequency meter for CFM or equivalent 4. Degaussing Coil Model 19--2000 from: Thordarson Meissner Inc. Electronic Center Mt Carmel IL 62863 5. High voltage probe for use with CRTs Fluke #80K--40 Cleaning 1. Rush Brush for cleaning contacts Brush part number BR4: refill part number AA0025 (Fine) Available from: The Eraser Company P.O. Box 4961 Syracuse, NY 13221 2. Vacuum Cleaner Hoover Model 57065060 or equivalent 3. 3.5/5.25 Disk Drive Cleaning Kit Recommend 3M or Byte Guard 4. Tape Drive Head Cleaning Kit FRSI P/N 1984--2154--0001 Tape Drive Head Cleaning Kit Refill FRSI P/N 1984--2154--0002 RS3: Maintenance Recommended Tools SV: 9-3-3 PeerWay 1. Twinax PeerWay Field Termination Kit FRSI P/N 1167--0016--0006. Fiber Optics 1. Fiber Optic Source and Power Meter. Stabilized Source Power Meter Model 9XT. Model 17XT Available from: Photodyne 1175 Tourmaline Drive Newbury Park, CA 91320 Phone: (818) 889--8770 or (805) 499--3636 RS3: Maintenance Recommended Tools SV: 9-3-4 RS3: Maintenance Recommended Tools RS3t Service Manual Chapter 10: Troubleshooting Section 1: Troubleshooting the Power System . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 Section 2: Troubleshooting a PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1 PeerWay Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plant Status Screen .............................................. PeerWay Performance Screen .................................... PeerWay Overview Screen ....................................... PeerWay Node Screen ....................................... PeerWay Node Screen General Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Interval Controller (TIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIC Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Broadcast Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point-To-Point Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Field Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Columns 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Column 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Node Screen Lower Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample PeerWay Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detecting a PeerWay Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the PeerWay Overview Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing a Console or SCI PeerWay Problem . . . . . . . . . . . . . . . . . . . . . . Diagnosing a ControlFile PeerWay Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . With One ControlFile on the PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Multiple ControlFiles on the PeerWay . . . . . . . . . . . . . . . . . . . . . . . . . . PeerWay Cable Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Twinax PeerWay Cables ........................... Troubleshooting Fiber Optic PeerWay Cables ........................ 10-2-1 10-2-2 10-2-3 10-2-9 10-2-12 10-2-13 10-2-13 10-2-13 10-2-14 10-2-14 10-2-14 10-2-14 10-2-14 10-2-15 10-2-15 10-2-15 10-2-19 10-2-21 10-2-23 10-2-25 10-2-29 10-2-30 10-2-31 10-2-33 10-2-35 10-2-36 10-2-37 10-2-37 10-2-39 10-2-40 10-2-41 10-2-42 RS3: Troubleshooting Contents SV: ii Section 3: Section 4: Section 5: Section 6: Troubleshooting Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1 General Console Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Power-Up Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Off-Line Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Controller Memory Dump Capture . . . . . . . . . . . . . . . . . . . . . . . . . . Other Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Memory Dump Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Node Dump Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Confidence Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRT Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting OI Card Cage Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2 10-3-3 10-3-8 10-3-12 10-3-12 10-3-14 10-3-15 10-3-16 10-3-19 10-3-20 10-3-21 10-3-22 10-3-24 Troubleshooting ControlFiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1 ControlFile Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wipe Bubble Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-7 10-4-9 Troubleshooting Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1 Restoring Redundant FICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Serial Input/Output . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Analog Input/Output . . . . . . . . . . . . . . . . . . . . . . . Field I/O Status Screen (FIC Status Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIC Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RBL Controller and Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-2 10-5-3 10-5-8 10-5-13 10-5-18 10-5-21 Troubleshooting PeerWay Interface Devices . . . . . . . . . . . . . . . . 10-6-1 OI Bubble Memory Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1 RS3: Troubleshooting Contents SV: iii List of Figures Figure Page 10.2.1. Plant Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-2 10.2.2. PeerWay Performance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-3 10.2.3. PeerWay Overview Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-9 10.2.4. PeerWay Node Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-12 10.2.5. PeerWay Overview Screen Under Normal Conditions . . . . . . . . . . . . . . 10-2-29 10.2.6. PeerWay Overview Screen with Fault Conditions . . . . . . . . . . . . . . . . . 10-2-30 10.2.7. Fault Detection on a PeerWay Overview Screen . . . . . . . . . . . . . . . . . . 10-2-31 10.2.8. Fault Detection on a PeerWay Node Screen . . . . . . . . . . . . . . . . . . . . . . 10-2-32 10.2.9. Fault Detection on a Peerway Overview Screen -- Example . . . . . . . . . 10-2-33 10.2.10. Fault Detection on a Peerway Node Screen . . . . . . . . . . . . . . . . . . . . . . 10-2-34 10.2.11. Peerway Overview Screen (PeerWay A Problem) . . . . . . . . . . . . . . . . . 10-2-40 10.2.12. Twinax “T” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-42 10.3.1. Console Power Up Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3 10.3.2. Console Off Line Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-8 10.3.3. Memory View Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-17 10.3.4. Node Dump Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-19 10.3.5. Menu Confidence Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-20 10.3.6. Video Signal Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-22 10.3.7. Checking Video Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-23 10.4.1. ControlFile Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-8 10.5.1. Field I/O Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-13 10.5.2. FIC Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-18 RS3: Troubleshooting Contents SV: iv List of Tables Table Page 10.1.1. AC/DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 10.2.1. Peerway Performance Screen Fields -- Part 1 . . . . . . . . . . . . . . . . . . . . 10-2-4 10.2.2. PeerWay Performance Screen Fields -- Part 2 . . . . . . . . . . . . . . . . . . . . 10-2-7 10.2.3. PeerWay Performance Screen Fields -- Part 3 . . . . . . . . . . . . . . . . . . . . 10-2-8 10.2.4. PeerWay Overview Screen Field Definitions . . . . . . . . . . . . . . . . . . . . . . 10-2-11 10.2.5. PeerWay Node Screen Definitions: Column 1 . . . . . . . . . . . . . . . . . . . . 10-2-15 10.2.6. PeerWay Node Screen Definitions: Column 1 ................... 10-2-17 10.2.7. PeerWay Node Screen Definitions: Columns 2 and 3 . . . . . . . . . . . . . 10-2-19 10.2.8. PeerWay Node Screen Definitions: Column 4 ................... 10-2-21 10.2.9. PeerWay Node Screen Definitions: Column 5 ................... 10-2-23 10.2.10. PeerWay Node Screen Definitions Lower Part ................... 10-2-25 10.2.11. PeerWay Node Screen Definitions: Bottom . . . . . . . . . . . . . . . . . . . . . . 10-2-27 10.3.1. Console Power Up Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-4 10.3.2. Console Off Line Diagnostic Menu Definitions . . . . . . . . . . . . . . . . . . . . 10-3-9 10.3.3. Memory View Screen Field Description . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-18 10.4.1. ControlFile Troubleshooting ................................... 10-4-2 10.5.1. Serial (MPC) I/O Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3 10.5.2. Multiplex I/O Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-5 10.5.3. RTD and Thermocouple I/O Troubleshooting . . . . . . . . . . . . . . . . . . . . . 10-5-6 10.5.4. Analog I/O Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-8 10.5.5. Analog I/O MUX Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-10 10.5.6. Analog I/O RTD and Thermocouple Troubleshooting ............. 10-5-11 10.5.7. Field I/O Status Screen Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-14 10.5.8. FIC/FIM Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-15 10.5.9. FIC/FIM Detail Screen Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-19 10.5.10. FIC/FIM Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-20 RS3: Troubleshooting Contents SV: 10-1-1 Section 1: Troubleshooting the Power System This section covers troubleshooting the AC and DC power supplies. Table 10.1.1 contains procedures for troubleshooting an AC/DC power supply. Table 10.1.1. AC/DC Power Supply Troubleshooting Condition PS FAULT (red LED) on. PS NORM (green LED) off. Amber AC IN lamp not on and no AC is present. Action 1. Turn BATT ON/OFF switch OFF. Disconnect the DC power plug at supply. Voltage should measure between 28 and 34 VDC. If not, replace the power supply. 2. Replace the battery charger board. BATT TEST FAULT (red LED) on. 1. Wait 60 minutes and press the BATT TEST pushbutton. NOTE: The power supply will continue to share the DC load without the battery or the battery charger board installed. 2. Open the battery compartment and determine if the battery connections are OK. NOTE: If the batteries show any sign of leaking, such as white corrosion on the battery posts, replace the batteries. 3. Check the fuse next to the battery compartment inside the power supply. 4. Replace the battery charger board. Wait for 60 minutes and press the BATT TEST pushbutton. 5. Replace the batteries. RS3: Troubleshooting Troubleshooting the Power System SV: 10-1-2 RS3: Troubleshooting Troubleshooting the Power System SV: 10-2-1 Section 2: Troubleshooting a PeerWay This section covers troubleshooting of the PeerWay: D PeerWay screens D Fault Diagnostics D Cable Faults PeerWay Screens These display screens give information useful in diagnosing PeerWay problems: RS3: Troubleshooting D Plant Status screen D PeerWay Performance screen D PeerWay Overview screen D PeerWay Node screen Troubleshooting a PeerWay SV: 10-2-2 Plant Status Screen The Plant Status screen (Figure 10.2.1 ) identifies the type of device located at each node on the PeerWay. To access the screen, type PS and press [ENTER] on the console keyboard. A backlit node number indicates that the node is “owned” by the console on which the screen is displayed. PLANT STATUS 29-Jul-88 07:30:45 First Node Listed> 1 Peerway Number> ALL Node Type Displayed > OWNED AND EXISTING NODES Node 1 CTL Norm 2 CTL Norm 4 MTCC 6 MTCC Node Node Node CONFIG 3 Figure 10.2.1. Plant Status Screen RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-3 PeerWay Performance Screen The PeerWay Performance screen shows PeerWay loading and performance. Call up the screen by entering PP - n, where “n” is the PeerWay number. The screen (and the related PeerWay Overview screen) can be configured to group the displayed nodes in Tap Box order. Use PP - 32 to call up a default screen with the nodes shown in numerical order. Use [SELECT] on a node number to call up the PeerWay Node screen for that node. Figure 10.2.2 shows the PeerWay Performance screen. Table 10.2.1 through Table 10.2.3 describes the fields on the screen. These fields are described in Table 10.2.1 . Node # Type ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® SUMpw Pway>1 If you change the PeerWay or node numbers, wait at least 5 seconds for the screen values to update. PEERWAY PERFORMANCE 25-Feb-91 12:07:37 Msgs_Point_KBit PW_Q_Buffers Links Host+PW&S+PWto PWto+Srvr+Srvr CPU Thk TxM,RxM TxK,RxK TxQ,RxQ,Free OutIn toPW+Svce+Host Srvr+Svce+toPW Idl Bsy These fields are described in Table 10.2.2. xxx,xxx xxx,xxx =Pxx% xx,xx =Lx% Data=xx% xx IdleM xxx=Txx% SlotW xx Margin xx Qual A xxx B xxx NdErr xx Time xxxx These fields are described in Table 10.2.3 Figure 10.2.2. PeerWay Performance Screen RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-4 Table 10.2.1. Peerway Performance Screen Fields -- Part 1 Definition Item Node # The first 16 node numbers are the same node numbers that are on the PeerWay Overview screen. If you change a node number here, it also changes on the PeerWay Overview screen. The first 16 numbers must be from the same PeerWay. Duplicate node numbers generate duplicate message counts. The last 8 node numbers can be any nodes 1-255. Node Type Shows the PeerWay node type. If the node type is white, the node is on the current PeerWay. The white nodes are used in the Sumpw load calculations. If the node type is green, the node is not on the current PeerWay. An * after the node type indicates the console that you are at. If the node type shows SLO followed by the first letter of the actual node type, in yellow, then the node has not responded within 2 seconds (same PeerWay) or 5 seconds (different PeerWay). The screen will display the last statistics from that node. These statistics are not used for the PeerWay sums. If the node type shows SLOW in yellow, then the node has not responded recently (within 2 seconds on the same PeerWay or 5 seconds on a different PeerWay) and does not have recent statistics to show. If the node type shows OLD followed by the first letter of the actual node type, in red, then the node has disappeared. The screen will display the last statistics from that node. These statistics are not used for the PeerWay Msgs_Point TxM, RxM TxM Shows the number of point-to-point messages sent by this node in the last 4 seconds. RxM Shows the number of point-to-point messages received by this node in the last 4 seconds. If the numbers include - or < (for example, 30--115, <93), then the number of point-to-point messages cannot be gathered for the node. Instead, other information is provided to give you a range of values that probably includes the actual number of point-to-point messages sent by the node. The first value shows twice the number of most of the point-to-point messages sent and received in the last second. (If the numbers include a <, then the first number is 0.) The second number shows the total number of all messages sent in the last 4 seconds. Point_KBit TxK, RxK TxK Shows the number of Kbits this node has used to send data (including headers) in the last 4 seconds. RxK Shows the number of Kbits this node has used to receive data (including headers) in the last 4 seconds. PW_Q_Buffers TxQ, RxQ TxQ Shows the number of 64-byte unit data highway (UDH) buffers that this node has queued up to send to the PeerWay in the last 4 seconds. RxQ Shows the number of 64-byte UDH buffers queued up for this node to receive from the PeerWay in the last 4 seconds. PW_Q_Buffers Free Shows the number of UDH buffers available for this node to send or receive on the PeerWay. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-5 Table 10.2.1. Peerway Performance Screen Fields -- Part 1 (continued) Item Links Out In Definition Out Shows the number of controller links requested from this node by other nodes. This value is the same as the “OutLinks” field on the PeerWay Node screen. In Shows the number of controller links requested by controllers in this node. This value is the same as the “InLinks” field on the PeerWay Node screen. Letters may appear between the Out and In values. Capital letters indicate the problem is more severe. Host to PW T or P Indicates problems in transmitting or receiving links. A, B, or P May indicate problems in a PeerWay Tap Box connection. Shows the average time (in msec) that it took over the last second for a request from this node to be sent on the PeerWay. Shows the same value as the “Host” field first value on the PeerWay Node screen. PW&S Svce If preceded by +, shows the approximate average time (in msec) that it took over the last second for a reply to a request from this node to be received by this node after the request was sent on the PeerWay. If preceded by =, shows the same value as the “Host” field second value on the PeerWay Node screen (Host to PW + PW&S Svce). PWto Host If preceded by +, shows the approximate average time (in msec) that it took over the last second for a reply received from a destination node to be serviced by this node after the request was received by this node. If preceded by =, shows the same value as the “Host” field third value on the PeerWay Node screen (Host to PW + PW&S Svce + PWto Host). PWto Srvr Shows the average time (in msec) that it took over the last second for this node as a server to start acting on a request after the node received a message from the PeerWay. Shows the same value as the “Server” field first value on the PeerWay Node screen. Srvr Svce If preceded by +, shows the approximate average time (in msec) that it took over the last second for a destination node to be ready to send a reply after the node started acting on a request. If preceded by =, shows the same value as the “Server” field second value on the PeerWay Node screen (PWto Srvr + Srvr Svce). Srvr to PW If preceded by +, shows the approximate average time (in msec) that it took over the last second for the destination node to send the reply on the PeerWay after the reply was ready to be sent. If preceded by =, shows the same value as the “Server” field third value on the PeerWay Node screen (PWto Srvr + Srvr Svce + Srvr to PW). (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-6 Table 10.2.1. Peerway Performance Screen Fields -- Part 1 (continued) Item CPU Idl Definition Shows the number of times (in thousands) that the node CPU goes through an idle loop each second. Shows the same information (in thousands) as the “Idletime” field on the PeerWay Node screen. Thk Bsy Shows the number of SentBUSY, GotBUSY, SentTHK, and GotTHK messages (combined). Shows a combination of the information in the “SentBUSY”, “GotBUSY”, “SentTHK”, and “GotTHK” fields on the PeerWay Node screen. An S after the value indicates that the value is all sends. A G after the value indicates that the value is all gots. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-7 Table 10.2.2. PeerWay Performance Screen Fields -- Part 2 Item Definition SUMpw xxx,xxx The first number shows the sum of the TxM fields of the white PeerWay nodes over the last 4 seconds. The second number shows the sum of the RxM fields of the white PeerWay nodes over the last 4 seconds. xxx,xxx The first number shows the sum of the TxK fields of the white PeerWay nodes over the last 4 seconds. The second number shows the sum of the RxK fields of the white PeerWay nodes over the last 4 seconds. =Pxx% xx,xx=Lx% Shows the percent of PeerWay bandwidth taken by point-to-point transactions (including slot wait time). The first number shows the sum of the Links Out fields. The second number shows the sum of the Links In fields. The third number shows the percent of PeerWay bandwidth taken by link messages (including slot wait time). Data=xx% This field shows the relative amount of space that actual data occupies in point and link transactions. Transactions take up slot wait time and header information in addition to actual data. This field shows the percent of the PeerWay bandwidth that would be used by the actual data if all of the idle messages were used by point and link transactions similar to the current transactions. xxx RS3: Troubleshooting Shows the sum of the Thk Bsy fields over the last 4 seconds. Troubleshooting a PeerWay SV: 10-2-8 Table 10.2.3. PeerWay Performance Screen Fields -- Part 3 Definition Item IdleM Shows the average of the idle messages at the PeerWay nodes over the last 4 seconds. =Ixx% Shows the percent of PeerWay bandwidth used by idle transactions. SlotW Shows the node slotwidth value. This is the same as the “slotw“ field value on the PeerWay Node screen. Margin Shows the node’s opinion of what the communication balance between the two PeerWays should be. This is the same as the “Margin” field value on the PeerWay Node screen. Qual A xxx B xxx Shows the node’s opinion of the quality of PeerWay A and PeerWay B. These are the same as the “Qual A” and “Qual B” field values on the PeerWay Node screen. NdErr xx Shows the sum of the internode errors on the PeerWay Overview screen. Time xxxx Shows the sum of the PeerWay-to-server response times for the white nodes, in milliseconds. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-9 PeerWay Overview Screen The PeerWay Overview screen (Figure 10.2.3) provides status information on all PeerWay nodes for both A and B PeerWays. It is intended to be used for diagnosing hardware and communication problems. Call up the screen by entering PO - n at the command line, where n is the number of the desired PeerWay. If the screen has not been configured you may call up a default screen by entering PP - 32 and then PO -- n. The default screen will display nodes in numerical order. PEERWAY OVERVIEW Pway ®6 ® >1 6 MTCC . ®4 ®1 ® ®2 ® ® ® ® ® ® 12-Dec-88 10:42:34 > Scroll Left ® ® ®A B 8 . . 8 363 ® 4 MTCC 1 CTL 7 . 9 9 7 . 9 . 6 8 5301 ® 380 ® 2 CTL . 9 . . 4 380 Force Margin®None 10:40:00 Actual Margin 9 Idle 1186 PeerWay B Problem 26 ® 7424 CONFIG 1 Figure 10.2.3. PeerWay Overview Screen The PeerWay Overview screen can display status information on as many as 32 nodes, the maximum number of nodes per PeerWay. Since only 18 nodes can appear on a single screen page, the remaining nodes can be displayed by scrolling left or right. Node numbers are displayed across the top of the screen below the screen title. Each node number in this row is preceded by an entry prompt, indicating that the nodes can be arranged in any order. The default condition has the nodes arranged in numerical order. NOTE: It is advisable to configure the node numbers in groups the same as they are actually located in the Tap Boxes in the field. This helps in troubleshooting PeerWay faults. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-10 Node numbers are repeated along the left hand side of the screen in the same order as they appear in the top row. Each node number in this column is followed by a code identifying the device (CTL=ControlFile; MC=MiniConsole; BCC=Basic Command Console; CC=Command Console; SCI=Supervisory Computer Interface, ...). Either a dot, a number, or two asterisks will appear at the intersection of each node’s column and row. A dot indicates no communication errors. If a number appears, it is the number of errors encountered by the device while communicating with all other nodes on the system. A pair of asterisks (**) indicates that more than 99 errors have been received from other devices. The A and B columns along the right hand side of the screen contain the corresponding node’s opinion of each of the two PeerWays (A and B). The numeral zero indicates a perfect PeerWay; increasing numerals represent increasingly degraded communications. For example, a reading of 100 is an advisory signal; a reading of 500 indicates extremely poor communications. The system will continue to perform without problems when only one PeerWay is performing badly. However, some messages may be lost if both PeerWays indicate readings above 500. There are also prompts along the right-hand side that allow the user to disconnect each node from one or both of the PeerWays for diagnostic purposes. Entering an A will open the local loopback relay at PeerWay tap A for that node. Entering a B will open the relay at PeerWay tap B. It is also possible to open both relays at the same time using an entry of AB. This feature is useful for diagnostic purposes. It allows the cable to be functionally disconnected from a node without having to actually remove the PeerWay drop cable. When AB is entered, the node is disconnected from the system and will not immediately respond to clearing (unless the request is made from the console on which the entry was made). The node will, however, time-out after one minute and begin communicating. If the AB command still exists in the entry field, the node will disconnect again. The A, B, and AB commands are cleared by cursoring to the entry field and depressing [ENTER] with no entry in the field or by leaving the screen. This clears the field and returns the node to normal operating status. Any number of nodes can be disconnected. However, it may be possible to disrupt the link exchange if an A and a B are entered on any one or two different nodes. Five additional fields are located along the bottom of the screen. They are: “Force Margin”, “Actual Margin”, “Idle”, and two fields containing error totals. Table 10.2.4 gives definitions of the fields. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-11 Table 10.2.4. PeerWay Overview Screen Field Definitions Item Definition Force Margin This is an enterable field that is used as an aid in determining the location of a fault. With this field, the user is able to increase the number of messages handled by either PeerWay and force the communications balance for the system of the automatic setting determined by a collective opinion of all the nodes in the system. Any value from 0 (all communications on PeerWay A) to 1000 (all communications of PeerWay B) can be entered. Under normal automatic operating conditions, the field will read “NONE” to indicate that there is no forced communication margin. On an operating system the Force Margin should not be changed more than 100 away from the Actual Margin reading. Actual Margin The number displayed in this field represents the distribution of messages between the two cables of the PeerWay. As with the Force Margin field, 0 indicates that all communication is taking place on PeerWay A; 1000 indicates that all communication is taking place on PeerWay B. When both PeerWays are working normally, the system will send messages on alternating PeerWays so each carries half of the traffic. The display will read 499 or 500. In case of a failure on one PeerWay, at least one percent of the communication will be attempted on the bad PeerWay to test to see if the failure has been repaired. Under fault conditions the “Actual Margin” will read 10 for a bad PeerWay B and 990 for a bad PeerWay A. Idle Numerical Fields This is the number of idle messages that are being sent on the PeerWay. Idle messages keep the PeerWay active when no broadcast or point-to-point messages are being transmitted. The last two fields on the PeerWay Overview screen contain the total number of communication errors for each of the PeerWays. When no Forced Margin is entered and the Actual Margin is not 500, the bad PeerWay can be identified easily by locating the largest total. To identify the bad node, enter a value about 50 units closer to 500 than the current Actual Margin reading. (If the margin is 990, enter 940; if it is 10, enter 60.) This forces enough errors so that it is easy to identify a pattern on the node error counters. There should be a clear cross pattern next to the bad node number. A vertical line of errors indicates a transmit problem on the node; a horizontal line indicates a receive problem. When multiple patterns appear on the screen, it is easier to identify a single pattern. Any nodes suspected of having errors can be dropped off the PeerWay system by entering AB next to the prompt in the right-hand column. This helps to eliminate confusing error counts on the PeerWay totals for clear identification. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-12 PeerWay Node Screen The PeerWay Node screen (Figure 10.2.4) is accessed by entering the PN command and a node number. Once a screen for a particular node is called up, all other nodes on the PeerWay can be accessed using [PAGE AHEAD] and [PAGE BACK]. PEERWAY NODE 02-Apr-90 Node Type Version 1 CTL 1270 Received 1671 Sent 266 Time 800 Received 0 Sent 0 Time 0 Msg/Sec 8 Overrun 0 Checksum 0 Abort 0 Badstat 0 Source 0 Bytecnt 0 Msgtype 0 Noecho 0 Badecho 0 LostLink 0 NoReply 0 XReply 0 Timeout 0 TooMany 0 Host Overrun Checksum Abort Badstat Source Bytecnt Msgtype Noecho Badecho LostLink NoACK XReply Timeout TooMany InLinks 0 OutLinks 0 Qual A Qual B Total A Total B Margin NoReply GotTIC Idletime Idlemsg Local 0 0 0 0 0 0 16 12127 1452 timer1 700 idelay Force Margin ® None 250 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Sync Behind Adjust BadLRC Size 0 0 0 0 0 SentLNRQ 0 GotLNRQ 0 SentREJ 0 GotREJ 0 SentBUSY 0 GotBUSY 0 SentTHK 0 GotTHK 0 NETerr 0 NoLink 0 LinkTime SlotTime 0 Server slotw 30 checkw Node Margin ® NONE 30 10:42:34 DupHOST DupHACK DupSERVE DupSACK DupNode AB Swap Coupler 0 0 0 0 0 0 0 HOSTfailn SERVfail Linkfail INfail OUTfail 0 0 0 0 0 TRANerr BadSOC BadNODE 1 14 31 0 0 0 checkd 0 Disconnect ® CONFIG 1 Figure 10.2.4. PeerWay Node Screen The PeerWay Overview screen, which was discussed on the previous pages, provides an easy method of identifying a faulty node or PeerWay. The PeerWay Node screen supplies greater detail on a specific node to help identify more subtle problems. If a redundant CP is used, the PeerWay Backup Node screen, which is virtually identical to the PeerWay Node screen, displays the redundant CP’s analysis of the PeerWay. To toggle between the PeerWay Node screen and the PeerWay Backup Node screen, press EXCHANGE. Many of the error counters on the PeerWay Node screen are intended for use by software development engineers and are of no practical use to the user. The shaded areas indicate the more important error counters for fault diagnostics. The error counters on this screen are time averaging. When an error occurs, it is logged on the screen. Most counters have a four second exponential decay and reflect the number of errors occurring during the last four seconds. If no additional errors occur, the total will eventually return to zero; if the errors occur at a steady rate, the error counter will hold at some value. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-13 NOTE: It is important to watch the screen for a period of time to see if the counters are increasing, decreasing, or holding steady. All of the error counters should return to zero in approximately one minute if a fault is corrected. PeerWay Node Screen General Definitions The following general concepts apply to the PeerWay Node and PeerWay Backup Node screens. Time Interval Controller (TIC) The Time Interval Controller (TIC) is the quarter second increment on which all PeerWay communication is based. Each 1/4th second, all communications between PeerWay nodes are resynchronized to a common time standard. TIC Master The TIC Master is the highest addressed priority active node on the PeerWay. The TIC Master: D Is the synchronizing node for the PeerWay D Maintains the PeerWay time D Determines when each TIC cycle is to begin D Calculates and dictates which PeerWay to use The TIC Master priority is determined by the: D Highest addressed Virtual Address Extension (VAX) D Highest addressed Highway Interface Adapter (HIA). D Highest addressed Multitube Console D Highest addressed Command Console D Highest addressed MiniConsole D Highest addressed PeerWay Interface (I/F) Node D Highest addressed ControlFile If the current TIC Master node disappears from the PeerWay, the next node in priority automatically picks up Time Interval Controller (TIC) Mastership to keep the proper sequence going. To determine the current TIC Master, look at the PeerWay Interface cards. The bottom yellow LED will be lit on the TIC Master node. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-14 NOTE: For multiple PeerWays, the highest numbered HIA on the lowest numbered PeerWay maintains the PeerWay time. The “Time Pass” field on the Configure HIA screen must be “Yes” for all HIAs. Host The Host is the node that makes the original request for data from a Server node. For instance, a console will be the Host when requesting values to update the fields on a graphic screen. Server The Server is the node that is the destination of the request of a Host message. When a console requests values for a graphics screen, the ControlFile acts as a Server to supply the data. Broadcast Messages Broadcast Messages are messages that are broadcast to all nodes. Acknowledge messages are not sent out from each receiving node for Broadcast Messages. However, if any of the link information is missing, it will be requested again in the form of a point-to-point message later in the TIC cycle. All ControlFile links are Broadcast Messages. Point-To-Point Messages Point-to-point messages are messages that are sent from a Host node to a specific Server node in order to request specific information for a Socket. Any requests for information for a console screen would be in the form of a point-to-point message. Socket A Socket is a task or process within a node that has a specific purpose in a Server node. For example, when a console has a graphic displayed, it will request specific values from a ControlFile for the graphics screen. The Host console will send a message to the ControlFile, with a specific message ID number, requesting the value. This request will be sent to a process within the controller (the Socket) for that data. The controller process will send the information from the Socket to the console host process with the message ID number attached for display on the graphic. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-15 Buffer A Buffer is a specific area of memory that is set aside to hold messages for temporary storage, until they are processed by a task within the node. PeerWay Node Screen Field Definitions The PeerWay Node and PeerWay Backup Node screens contain five columns of error counters, a lower portion of average values, and a bottom row of enterable fields. Each item on the screen is defined below. PeerWay Node Screen Column 1 Table 10.2.5 gives definitions of items in column 1. Table 10.2.5. PeerWay Node Screen Definitions: Column 1 Definition Item Node Node number represented by the error counters on screen Type Indicates the type of node: MC MiniConsole CTL ControlFile MTCC Multitube Console CC Command Console SCI Supervisory Computer Interface SRU System Resource Unit HIA Highway Interface Adapter RFI Rosemount Factory Interface DIOG Diogenes Interface VAX RS3 PeerWay QBus Network Version PeerWay software level for this node. This version will be the same as the software level for the device. Msg/Sec Total number of point-to-point messages transmitted per second; should be at least eight (the screen is updated four times per second). InLinks Number of controller links requested by controllers in this node. Add this number and the value in the “OutLinks” field. The result should be the same as the number of links reported on the ControlFile Status screen for the CP “Avail Links”. This field, and the “OutLinks” field below, can be used to get a link count of links going through an HIA (which has a limit of 40 links). OutLinks Number of controller links requested by other nodes from this node. Add this number and the value in the “InLinks” field. The result should be the same as the number of links reported on the ControlFile Status screen for the CP “Avail Links”. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-16 The following five fields contain quality opinions on the PeerWay. An indication of 0 represents a perfect PeerWay where 6000 means very little useful data can be sent or received. If any node’s opinion of either PeerWay shows errors, communication will move towards the good PeerWay. If the quality of both highways is showing errors, the communications will attempt to find a reasonable medium between the two PeerWays. The actual Quality numbers for each particular node are derived from a large number of the error indications shown on the PeerWay Node screen. The Total Quality number for each PeerWay is calculated by each node from the individual Node Quality readings. The TIC Master will then dictate, from these numbers, what the “Actual Margin” should be for PeerWay Communications. Each node enters its own opinion of what the margin should be based on its success in talking to the other nodes on the PeerWay. The Margin for each node can be manually entered for diagnostic purposes by entering a value (0 to 1000) in the “Node Margin” field at the bottom of the screen. The TIC Master determines the “Actual Margin” by comparing the “Node Margins” of all consoles on the PeerWay. This value is displayed on the PeerWay Overview screen. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-17 Table 10.2.6. PeerWay Node Screen Definitions: Column 1 Item Definition Qual A This node’s opinion of the quality of PeerWay A. Qual B This node’s opinion of the quality of PeerWay B. Total A Collective quality opinion of PeerWay A from all PeerWay nodes. Total B Collective quality opinion of PeerWay B from all PeerWay nodes. Margin This node’s opinion of what the communication balance between the two PeerWays should be. A value of 0 indicates all communications are on PeerWay A. A value of 1000 indicates all communications are on PeerWay B. The Console with the highest PeerWay address determines the Actual Margin (displayed on the PeerWay Overview screen). If this Console is lost, the highest addressed ControlFile will determine the Actual Margin. GotTIC Number of TIC messages received over the last 4 seconds (should always be 16) IdleTime The number of times that the node processor goes through an idle loop each second. This value indicates how busy the node processor is. A number in the hundreds indicates that the processor is very busy. Normal operation is indicated by values of at least several thousand. The number can vary greatly, depending on the node type and processor used and the amount of load on the processor and its use. For instance, a 68000 Console displaying a Menu Command Console screen will show an approximate IdleTime of 10,000, whereas a 68020 console with the same screen will show a value of about 100,000. Either console will normally show an IdleTime of 0 when a busy graphic is displayed. The processor is spending all of its time updating the graphic. This is normal and expected. There is no other screen that gives the relative ”processor” idle time reading for many node types such as the console or PeerWay Interface devices. For a ControlFile node, depending on the image used, the readings will vary depending on load. These readings should roughly coincide with the CP Idle time as displayed on the ControlFile Status screen. The IdleTime for a CPMax Image with a normal Controller load might be about 15,000 (75% idle time on the ControlFile Status Screen). This number will drop as one or more consoles or PeerWay Interface devices (such as SCI, QBI, etc.) begin to draw information from the node. The IdleTime for a CPBATCH image will drop to near 0 as soon as one or two Batch tasks are started (at Priority 1000). The CP is using all of its available idle time to operate the batch tasks. As more console screens and PeerWay nodes request information from the CP, the batch tasks are updated less often in order to answer the console requests. This is normal and expected. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-18 Table 10.2.6. PeerWay Node Screen Definitions: Column 1 (continued) Item Definition Idlemsg This is the number of idle messages received on the PeerWay by this node. When all Link, Broadcast and Point to Point messages (higher priority messages) are completed the remainder of the 1/4 second TIC cycle is filled with idle messages to allow for better diagnostics of the PeerWay. Idle messages are used to maintain diagnostics of the PeerWay and to maintain 100% PeerWay usage. The added messages allow for more accurate error reporting during times when no other broadcast or point-to-point messages are being sent. The Idlemsg reading is a good indication of how much bandwidth is available on the PeerWay. As more nodes and message loading are added to the PeerWay, the Idlemsg reading will drop. For a single node PeerWay, such as a single console, the Idlemsg reading will be about 765. An average 15 node system may run about 400 Idlemsgs. However, a high number of message requests will cause this number to drop. If 8 Consoles were all accessing busy graphic screens, this number could easily drop to 300. Other nodes such as QBI or SCI that can also make very large point-to-point message requests can also drop the Idlemsg to a low number. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-19 PeerWay Node Screen Columns 2 and 3 Columns 2 and 3 contain the same error counters. Column 2 is representative of PeerWay A and column 3 of PeerWay B. Table 10.2.7 shows definitions of items in columns 2 and 3. Table 10.2.7. PeerWay Node Screen Definitions: Columns 2 and 3 Definition Item Received The number of PeerWay messages received by this node on the PeerWay. The number of messages on PeerWay A plus PeerWay B is the total number of messages on the PeerWay. As the PeerWay Actual Margin changes, the messages received will reflect the difference in PeerWay access. Sent The number of messages sent by this node on PeerWay A (column 2) and PeerWay B (column 3). Time The “Time” number is an indication of the relative amount of time this node spent listening for messages on PeerWay A (column 2) or PeerWay B (column 3). Under normal conditions, the ratio of time spent on each PeerWay and the messages received on each PeerWay should be the same. If the Time number on one PeerWay is inappropriately large, there may be a problem on that PeerWay. Overrun The number of overrun errors detected by the communications chip on the node. An overrun error is usually caused by a failure of the Direct Memory Access Controller (DMAC) chip to take in the characters as fast as the communications chip can provide them, resulting in a message that is too long. Checksum The number of Cyclical Redundancy Check (CRC) errors detected by this node. This is a standard method used to verify that each message is received at the server node exactly as it was sent by the host node. Each message that is sent on the PeerWay has multiple data validity checks, including the CRC. If a message received is corrupted in any way, the data is requested again from the host node. These errors could be caused by some form of temporary message collision resulting in corrupted message to a node. Abort A message was aborted due to an improper sequence of closing flag in the message termination into the Communications chip. The message will be requested again. Badstat A bad message status was detected by the Serial Communications Controller in a message received. The message status may be a framing error or other improper data detected by the communications controller. Source The source node field received in a packet was corrupted. Bytecnt The count of the number of bytes is another in a series of data verifications checks. This error counter is detected by the Communications chip, and indicates that the byte count field in a packet did not match the packet length. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-20 Table 10.2.7. PeerWay Node Screen Definitions: Columns 2 and 3 (continued) Item Definition Msgtype The message type field received in a packet did not contain a valid message type value. Noecho As each message is transmitted from this node, the node itself will receive the message and verify it. If the message is not received at all, it is indicated by a “Noecho” error. This error would normally indicates a problem between the PeerWay Interface card and the Tap Box of this node. The PeerWay Overview screen will show errors for this node. Badecho As each message is transmitted from this node, the node itself will receive the message and verify it. If the message is corrupted, it is indicated by the “Badecho” error. This error would normally indicate a problem between the PeerWay Interface card and the Tap Box of this node. The PeerWay Overview screen will show errors for this node. LostLink If, by 90% of the way through the TIC, the Link rerequest message (see SentLNRQ) messages are still not received, the node bumps the LINKLOST counter to indicate there was a problem. All nodes keep track of all messages on the PeerWay because it affects the transmit priority scheme on the PeerWay. NoReply This node heard a point-to-point message or an LNRQ message requesting an immediate reply, but did not hear the reply from the server node. All nodes keep track of all messages on the PeerWay because it affects the transmit priority scheme on the PeerWay. XReply This node heard a reply to a point-to-point message or an LNRQ message from a Server node, but did not hear the original request for the message. All nodes keep track of all messages on the PeerWay because it affects the transmit priority scheme on the PeerWay. Timeout This indicates no messages were heard on this PeerWay for a specific amount of time. TooMany The node processor has received interrupts from the PeerWay too quickly and has been forced to stop processing some of the interrupts. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-21 PeerWay Node Screen Column 4 Table 10.2.8 gives definitions of items in column 4. Table 10.2.8. PeerWay Node Screen Definitions: Column 4 Definition Item Sync More than five messages in a row were lost and this node cannot tell which node has permission to transmit. This node will request that the system reset the transmission priority beginning with node one. Could indicate a PeerWay drop cable is disconnected from a node. Behind The DMAC cannot keep up with the rate of data being received on the PeerWay. Possibly caused by a processor that is overloaded and does not have enough idle time to keep up with the PeerWay. This is an error condition generated from the DMAC. Adjust The timing of the software clock of the node was adjusted in order to stay in sync with the other nodes on the PeerWay. Each node adjusts itself regularly to keep its time in sync with the TIC Master time adjustment. Displays of a value of 1 or 2 under are normal and sometimes even higher, depending on the Time Correction entered on the TIC Master. Larger numbers may indicate a problem with the synchronous frequency of the node’s clock. Even with large numbers in this field, there should be no adverse effect on the PeerWay. BadLRC Size The Linear Redundancy Check (LRC) is a data validation check used when moving data from the Direct Memory Access Controller (DMAC) RAM into the main memory of the node. The BadLRC indicates that an LRC error has occurred. This may indicate a bad DMAC or RAM on the node with the largest number of errors in this field. Message size of the packet is not consistent with other data in the message packet at the network level. The message will be automatically requested again. An apparently correct message was received, but the size of the packet is not consistent with other data in the packet. SentLNRQ The LINK Broadcast message is sent by all nodes between 20% and 60% of the way through each TIC cycle. All nodes must hear the LINK messages sent by all other nodes, or they send LNRQ messages to request a retransmission at 60% of the way through the TIC. It is expected that the message will be transmitted in this TIC cycle. GotLNRQ This Server node received a point-to-point message request for a link message that was not correctly received at the destination node in the link packet. This node is the destination of the SentLNRQ message. SentREJ An LNRQ was received before 20% or after 90% of the way through the TIC Interval. At this time the LINK message cannot be retransmitted, so this node sent a REJ message in place of the requested LINK message. The other node will now realize that there is a clock synchronization problem and hold off asking for the LINK again until the next TIC. GotREJ This node received a REJ message in response to an LNRQ message, indicating that its clock is desynchronized relative to the clock in the other node. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-22 Table 10.2.8. PeerWay Node Screen Definitions: Column 4 (continued) Item Definition SentBUSY This Server node received the message correctly, but the PeerWay buffer is full so the message cannot be handled at this time. The Host node will have to send the message again at a later time when there is room in the PeerWay buffer. This situation can be caused by an abnormally busy processor. There will be a Host node (or nodes) somewhere on the PeerWay that indicates “GotBUSY” messages. This is the node that requested the information. GotBUSY This Host node sent a message to a Server node with a full receive buffer. That Server is the source of a “SentBUSY”, indicating that the message cannot be answered at this time. SentTHK This Server node received a message and passed it off to a Socket (internal process) within the node to get the requested information, but information has not been returned from that process. This message acknowledges to the Host node that the message was received and is being acted upon but has not yet responded by the Socket. There will be a Host node on the PeerWay showing “GotTHK” messages. This Host is the target of the “SentTHK” messages. GotTHK This Host node received a message indicating the Server node has requested the message information from an internal process, but has not yet received the reply. (See SentTHK.) NoACK A requested low level acknowledge to a point-to-point message was not received. The message must now be retransmitted. NoLink A LINK message response to an LNRQ message (see SentLNRQ) was not received. The Link packet will be sent again until the LINK is received, or it becomes too late in the TIC interval for the information to be useful (see SentREJ). LinkTime This is number of times this node heard a link message in a portion of the TIC cycle not intended for link messages. It indicates a node may not be synchronized properly. SlotTime Each node is allowed a small portion of time (a Slot Width) in the TIC cycle to transmit information, beginning with node 32 and, in turn, allowing this small period of time for each node (if the node number exists) to begin transmitting on the PeerWay. All nodes listen for a specific node number to transmit within each node’s SlotTime. If this node hears one node transmit in another node’s SlotTime, an error is entered in this field. SlotTime errors are typically not a serious problem. They may be due to a processor clock chip being slightly off frequency. A large number of SlotTime errors may be caused by a bad tap. To isolate the tap, force the margin and observe the errors. If the errors go to zero, the problem is on the PeerWay with no traffic. For an Optical PeerWay, the errors may indicate that the “Slot Width” entry on the Configure Command Console screen or Configure HIA screen may be too low, not allowing sufficient time for each node to transmit, especially if there is a large break in the node numbering (such as node 30 down to node 2). Excessive “Slot Width” entries will decrease the “Idlemsg” so a reasonable number must be chosen. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-23 PeerWay Node Screen Column 5 Table 10.2.9 gives definitions of items in column 5. Table 10.2.9. PeerWay Node Screen Definitions: Column 5 Definition Item DupHOST The Server has received duplicate Host messages in response to a request. This may be due to the Host not receiving the Server acknowledge message. DupHACK When a Host requests a message from a Server node, the Server node will acknowledge back to the Host that the message was received. The Host will in turn acknowledge that it received the Server’s acknowledgement of the request. Errors indicated here show that duplicate acknowledgements from the Host were received. DupSERVE Errors here indicate that a duplicate messages reply from the Server was received by the Host in response to the Host request. DupSACK When a Host requests a message from a Server node, the Server Node will acknowledge back to the Host that the message was received before the actual message is returned. Errors indicated here show that duplicate acknowledgements from the Server were received. DupNODE Two separate nodes on the PeerWay are sending messages, using the same node number. A large number of errors indicates that two nodes are addressed with the same node number. An alarm “PeerWay Duplicate Node” will also normally accompany errors in this field. AB Swap Indicates the number of PeerWay A messages that were received on PeerWay B or PeerWay B messages received on PeerWay A. A large number here indicates A and B twinax cables or optical fiber are swapped. There will also be a large number of errors indicated on many nodes on the PeerWay Overview screen. Coupler This error indication shows that some hardware error has been detected on the Coupler Status line coming from the PeerWay Tap Box, PeerWay Interface, or ControlFile PeerWay Buffer. It will be triggered from a Watchdog Time-out (node tried to transmit on the PeerWay too long), or a hardware failure that has been detected by the ControlFile PeerWay Buffer. There is also a RED LED tied to this line on the ControlFile PeerWay Buffer and PeerWay Interface (for consoles and all other nodes) that would normally indicate which PeerWay is at fault. A large number of errors on this field normally indicates there is a hardware problem with this node. Possibly a bad tap cable connection to the Tap Box, or bad Tap Box, PeerWay Buffer or Interface. HOSTfail A Server transmitted the data to the Host but no Host acknowledge message was received after repeated attempts. Without the Host Acknowledge, the Server keeps sending the message until it gets the Host Ack message or until the PeerWay time-out expires indicating that that node has not transmitted on the PeerWay for longer than 4 seconds. This error may occur when node tries to send a reply to a node that has dropped from the PeerWay. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-24 Table 10.2.9. PeerWay Node Screen Definitions: Column 5 (continued) Item Definition SERVfail When a Host makes a request for data from a Server node, it expects an acknowledge message from the Server indicating that the message was received. If that message is not received after repeated attempts, the Host indicates an error here. LINKfail Despite all LNRQ retry attempts, the expected LINK packet from another node was not received after 90% of the TIC interval. Any control blocks in the system requiring data in this LINK message will receive an invalid link indication. INfail A ControlFile has requested more than 40 links from other ControlFiles on the PeerWay(s). OUTfail A ControlFile has requests for more than 40 links from other ControlFiles on the PeerWay(s). This will coincide with the negative links reading for the CP on the ControlFile Status (CFS) screen and ControlFile Links screen. NETerr An error here indicates an error that was detected at the Network level. The Network levels are the lower layers (last 4 layers) of data applied to the communications message that applies the Host and Server address, header type, checksums and which bus to use next. The message will be transmitted again. TRANerr Transport level of protocol error was detected. The transport level is the inner level of data. This is the level where the socket data and message type is put together for transmission on the PeerWay. BadSOC Data sent in a message socket to this node could not be used because there was no process within the Host node that could use the data. BadNODE This node tried to send a message to another node that is not on the active node list. The active node list contains all nodes that have transmitted on the PeerWay during the last four seconds. This field may also indicate an error when 50 retries have not produced an acknowledgement. Errors will often be seen here for a short period of time after a node disappears from the PeerWay. If a console node is requesting trend information for a node that does not exist or some other similar request from an SRU, SCI, VAX, etc. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-25 PeerWay Node Screen Lower Part The next eight fields are located below the columns of the PeerWay Node screen. Times are averages for all messages received in the last second. Table 10.2.10 gives definitions for items in the lower part of the screen. Table 10.2.10. PeerWay Node Screen Definitions Lower Part Definition Item Local Some message requests for information within the same node are done through the PeerWay subsystem, but the message is never actually transmitted on the PeerWay. This is the timer for requests being requested from within this node. Timers begin when the message is sent by Host and seen by the PeerWay subsystem. The first of the three numbers indicates how many milliseconds it takes for the process request message to be received by the Server Process within this node. The second number is how many milliseconds it takes for the reply from the Server Process within this node to be queued in the PeerWay subsystem. The third number is how many milliseconds it takes to get the reply to the Host process. NOTE: Times 2 and 3 will not exist for a simplex message and simplex point-to-point messages such as Alarm messages or trackball movement messages that do not have a corresponding response. Times 2 and 3 are not updated for these messages. Host This is the time it takes for this node as a Host node to make requests of a Server node. Timers begin when the message to be send by the Host process to the Server Node is queued on the PeerWay. The first of the three numbers indicates how many milliseconds it takes for the process request message to be transmitted on the PeerWay subsystem. The second number is how many milliseconds it takes for the Server process to respond and queue the message in the PeerWay. The third number is how many milliseconds it takes to receive the reply at the Host process. High time indications in: The first number means PeerWay is loaded, message is not getting out. The second number means the server is loaded The third number means the host is loaded NOTE: Simplex point-to-point messages such as Alarm messages or trackball movement messages do not have a corresponding response, so times 2 and 3 are not updated for these messages. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-26 Table 10.2.10. PeerWay Node Screen Definitions Lower Part (continued) Item Server Definition The node that is answering the request from a host node. Timer begins when the message is received from the Host and is queued to the Server process. The first of the three numbers indicates the time in milliseconds (1000 = one second) when the queued message was received by the Server process. The second number is the time in milliseconds for the Server process to reply to the message and the response to be queued for transmission on the PeerWay. The third number is the time in milliseconds that it takes to get the reply message transmitted on the PeerWay. NOTE: Simplex point-to-point messages such as Alarm messages or trackball movement messages do not have a corresponding response, so times 2 and 3 are not updated for these messages. timer1 The length of the fixed time interval in units of 1/2 microsecond, which is used as a setup time for sending messages, after the previous node has completed its message. Nominal value is fixed at 700. idelay The number of slot times the TIC Master must wait before it will begin the cycle of sending idle messages (see Idlemsg). The nominal value is 250 and will vary with the Slot Width entry. slotw This is the slotwidth reading in units of 1/2 microsecond. This value is enterable on the Configure Command Console screen or Configure HIA screen. The nominal entry for this value is 30. Entry may be a minimum of 20 (see SlotTime and fields on the HIA screen). checkw This value is used as a back calculation to verify that nodes on the PeerWay are transmitting within their correct slot time. The checkw value is in units of 1/2 microsecond. The checkw value will follow the Slot Width entry. A Slottime error is generated using: (actual -- expected + checkd) < checkw checkd The checkd allows for a propagation delay on the PeerWay. The slot time window minimum delay value is in units of 1/2 microsecond. The nominal value is 0. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-27 The last four fields are located along the bottom of the PeerWay Node screen. Table 10.2.11 gives definitions for items located at the bottom of the screen. Table 10.2.11. PeerWay Node Screen Definitions: Bottom Definition Item Force Margin This is an enterable field that allows the user to force this node’s opinion of the communications quality is for the PeerWays. This is nominally set to “None”. The TIC Master determines the Actual Margin for the PeerWay, based on the Node Margin of all existing nodes. This field may be used as an aid in determining the location of a fault. Any value from 0 (all communication on PeerWay A) to 1000 (all communication on PeerWay B) can be entered. During normal operation, this field indicates “NONE”. The Force Margin should not be changed more than 100 away from the Actual Margin setting on an operating process. Should one PeerWay have a fault, all but 1% of the communications will be on the good PeerWay. The 1% on the bad PeerWay will allow the system to detect if the bad cable is repaired and to allow it to change back to sharing PeerWay communications. The 1% of messages sent on the bad PeerWay will be requested again on the good PeerWay. With a bad PeerWay, it is sometimes hard to distinguish which node is at fault with only the 1% error rate. A slightly higher value error rate may be entered by changing the Force Margin, from 10 to 50. By adjusting the Force Margin slightly, the number of error indications should rise so the pattern is more obvious. Do not move the Force Margin by large amounts. Node Margin This field indicates this node’s opinion of what the automatic setting of the Actual Margin should be in the system Actual Margin evaluation scheme (see Force Margin) A value of 500 indicates that this node sees no errors on either highway. A value of 0 indicates that this node cannot get any messages through on PeerWay B and is requesting all communications on PeerWay A. A value of 1000 indicates that this node cannot get any messages through on PeerWay A. (continued on next page) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-28 Table 10.2.11. PeerWay Node Screen Definitions: Bottom (continued) Item Disconnect Definition This field is used to remotely disconnect this node from the PeerWay for diagnostic purposes. It may be used to try to determine which node might be shorting the PeerWay cable, or causing the errors seen on the PeerWay Overview screen, without physically removing the PeerWay drop cables. It allows the user to disconnect this node from either or both PeerWays for diagnostic purposes. Entering “A” will open this node’s local loopback relay at PeerWay Tap A. To disconnect PeerWay B, the operator enters “B”. Entering “AB” disconnects both PeerWays. If “AB” is entered for a Console node, the console will be disconnected from both PeerWays. As soon as the “AB” is removed, the console will again begin communicating on the PeerWays. If the “AB” is entered for any node, other than the console itself, the node will time out after one minute and reconnect with the PeerWay. If the “AB” command still exists on the screen, the node will again be disconnected. The “AB” command is cleared by cursoring to the field above the command and pressing [ENTER]. If you change screens, the disconnect (“A”, “B”, or “AB”) is automatically removed from the field. This same feature is available on the PeerWay Overview screen for all nodes on the PeerWay. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-29 Sample PeerWay Problems Figure 10.2.5 shows an example of how a Peerway Overview screen should appear when no faults exist on the PeerWay. The matrix should show all dots, and the A and B column on the right side should be all zeros, including the total at the bottom. The “Force Margin” should be “None” and the “Actual Margin“ should be 499 or 500. Note how the nodes have been grouped together. The nodes have been configured this way to indicate how they are physically located along the PeerWay and which nodes are connected together on a common Tap Box. Pway >1 01 CTL 02 CTL 04 CTL PEERWAY OVERVIEW ®1 ®2 ®4 ® ®10®12®14®32® ®6 ®8 ® ® 02-Apr-90 >Scroll ® ® ® A 0 0 0 10:42:34 Left B 0 0 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . BCC CC CC MC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 0 0 0 0 0 0 0 06 SCI 08 CTL . . . . . . . . . . . . . . . . . . 0 0 0 0 10 12 14 32 Force Margin®None Actual Margin 499 Idle 1186 ® ® ® ® ® ® ® ® ® --- --0 0 CONFIG 1 Figure 10.2.5. PeerWay Overview Screen Under Normal Conditions RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-30 PeerWay Fault Conditions Figure 10.2.6 shows a Peerway Overview screen with three fault conditions. 1. “PeerWay B Problem” Alarm on the Alarm line. 2. “Actual Margin” at the bottom center of the screen shows a value other than 499 or 500. A value below 499/500 indicates B PeerWay is bad and A PeerWay is handling all communications. A value above 499/500 indicates A PeerWay is bad and B PeerWay is handling all communication. 3. A and B PeerWay totals at the lower right hand corner of the screen indicates the bad PeerWay by the larger number. PEERWAY OVERVIEW Pway 1 2 4 >1 01 CLT . . . 02 MC . . . . . 2 . . 2 . . . . . . 8 6 363 380 04 MC . . . . 4 . . . . 8 380 06 10 12 14 . 1 . . . . .2 . . . . . 2 . . . . 4 . . 3 . 6 4 4 2 380 5301 166 200 . . . . . . . 4 8 380 363 --- --- 5 923 CC CTL MC MC 16 CC 32 MC Force Margin 6 10 12 12:24:06 16 32 . . . 1 1 1 . . . . . . 3 . . . 3 . . None 14 02-Apr-90 12:24:06 >Scroll Left A B 1 . . . . Actual Margin 8 Idle 1176 PeerWay B Problem OPER 1 Figure 10.2.6. PeerWay Overview Screen with Fault Conditions RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-31 Detecting a PeerWay Fault Figure 10.2.7 shows how to determine the node number suspected of causing a fault. 1. Observe the “= 10 PeerWay Node Problem” Alarm on the Alarm Line. 2. Error number indications on the screen matrix in a straight vertical or horizontal pattern or both a vertical and a horizontal pattern (as shown). If a clear pattern is not distinguishable, the Margin can be forced. This requires use of a Configuror’s Key. The margin must not be forced more than 50 away from the “Actual Margin” reading. At this point you now know the bad PeerWay (B) and node number (=10). Proceed to the proper troubleshooting procedure. Pway PEERWAY OVERVIEW 1 2 4 6 10 12 14 02-Apr-90 12:23:56 >Scroll Left A B 16 32 >1 01 CLT 02 MC . . . . . . . 4 4 . . . . . . . . 10 17 04 MC . . . . 5 . . . . 12 06 CC 10 CTL . . . . 3 2 2 5 1 . . 3 2 . . 2 2 17 6 0 1316 12 MC . . . . 6 . . . . 10 0 14 MC . . . . 6 . . . . 10 0 16 CC 32 MC . . . . . . . . 7 5 . . . . . . . . 17 14 0 0 ---- ---- 13 180 Force Margin 12:23:54 None =10 1 Actual Margin 11 Idle 1220 PeerWay Node Problem 0 0 OPER 1 Figure 10.2.7. Fault Detection on a PeerWay Overview Screen Figure 10.2.8 shows the ControlFile PeerWay Node screen for the previous fault example for node 10 (as shown in figure 2--6). Note that for every message sent on PeerWay B (third column from the left) there is a “Badecho” count. The “Coupler” status error count is also very high, which indicates errors coming from the PeerWay Tap box or PeerWay Buffer card. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-32 PEERWAY NODE 02-Apr-90 8:28:16 Node Type Version 10 CTL 1270 Received 2190 Sent 250 Time 1102 Received 0 Sent 12 Time 14 Msg/Sec 13 Overrun 0 Checksum 0 Abort 0 Badstat 0 Source 0 Bytecnt 0 Msgtype 0 Noecho 0 Badecho 0 LostLink 0 NoReply 0 XReply 0 Timeout 1 TooMany 0 Host Overrun Checksum Abort Badstat Source Bytecnt Msgtype Noecho Badecho NoACK NoReply XReply Timeout TooMany InLinks 0 OutLinks 0 Qual A Qual B Total A Total B Margin 0 6000 0 1402 0 GotTIC 16 Idletime 11976 Idlemsg 1322 Local timer1 700 idelay Force Margin ® None 250 0 0 0 0 0 0 0 0 12 12 2 0 0 0 Sync Behind Adjust BadLRC Size 0 0 0 0 0 SentLNRQ 4 GotLNRQ 2 SentREJ 0 GotREJ 0 SentBUSY 0 GotBUSY 0 SentTHK 0 GotTHK 0 NoReply 0 NoLink 0 LinkTime SlotTime 0 Server slotw 30 checkw Actual Margin ® NONE 30 DupHOST 0 DupHACK 0 DupSERVE 0 DupSACK 0 DupNode 0 AB Swap 0 Coupler 1024 HOSTfailn SERVfail Linkfail INfail OUTfail 0 0 0 0 0 NETerr TRANerr BadSOC BadNODE 1 14 31 0 0 0 0 checkd 0 Disconnect ® CONFIG 4 Figure 10.2.8. Fault Detection on a PeerWay Node Screen RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-33 Using the PeerWay Overview Screen The Peerway Overview screen in Figure 10.2.9 shows that Node 2 is bad. The “Actual Margin” and “A Totals” fields indicate that PeerWay A is bad. Pway PEERWAY OVERVIEW 02-Apr-90 12:23:56 >Scroll Left A B >1 01 CLT 02 MC 04 MC 1 2 4 6 10 12 14 16 32 . 5 . 1 1 1 . 4 . . . 1 1 . . . 3 . . 3 . . 1 . . 1 . 258 6000 303 10 5 3 06 10 12 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 181 179 246 3 3 0 0 . . . . . . . . . . . . 307 303 0 3 CC CTL MC MC 16 CC 32 MC 3 3 4 2 . . . . . 5 . . 4 . Force Margin None 13:12:49 =02 Actual Margin 975 Idle 1000 ---- ---- 1180 5 PeerWay Node Problem OPER 1 Figure 10.2.9. Fault Detection on a Peerway Overview Screen -- Example Figure 10.2.10 shows the PeerWay Node screen for Node 2 under the same fault condition. Note that for every message sent on PeerWay A (second column from the left) there is a “Noecho” error count. This screen indicator (or “Badecho” counter) can be used for quick reference during troubleshooting. Note the “Noecho” counts and the “Coupler” errors. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-34 PEERWAY NODE 02-Apr-90 8:28:16 Node Type Version 2 MC 1270 Received 0 Sent 16 Time 15 Received 2186 Sent 214 Time 1010 Msg/Sec 41 Overrun 0 Checksum 0 Abort 0 Badstat 0 Source 0 Bytecnt 0 Msgtype 0 Noecho 16 Badecho 0 LostLink 0 NoReply 0 XReply 0 Timeout 0 TooMany 0 Host Overrun Checksum Abort Badstat Source Bytecnt Msgtype Noecho Badecho LostLink NoReply XReply Timeout TooMany InLinks 0 OutLinks 1 Qual A Qual B Total A Total B Margin 6000 0 1423 1 1000 GotTIC 16 Idletime 18 Idlemss 1326 Local timer1 700 idelay Force Margin ® None 13:12:49 =02 250 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Sync Behind Adjust BadLRC Size 0 0 0 0 0 SentLNRQ 3 GotLNRQ 2 SentREJ 0 GotREJ 0 SentBUSY 0 GotBUSY 0 SentTHK 0 GotTHK 0 NoACK 0 NoLink 0 LinkTime 0 SlotTime 0 Server slotw 30 checkw Node Margin ® NONE PeerWay Node Problem 30 DupHOST 0 DupHACK 0 DupSERVE 0 DupSACK 0 DupNode 0 AB Swap 0 Coupler 1024 HOSTfailn SERVfail Linkfail INfail OUTfail 0 0 6 0 0 NETerr TRANerr BadSOC BadNODE 1 14 31 0 0 0 0 checkd 0 Disconnect ® OPER 1 Figure 10.2.10. Fault Detection on a Peerway Node Screen RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-35 PeerWay Fault Diagnostics Procedures are given below for troubleshooting PeerWay problems for: D Console or SCI PeerWay Problem D ControlFile PeerWay Problem: — With one ControlFile on the PeerWay — With multiple ControlFiles on the PeerWay These troubleshooting procedures are designed for a technician who has attended the RS3 maintenance class. It is assumed that the proper procedures are always followed when removing or installing modules in the system. It is also assumed that anyone working on the system is familiar with the plant process operations and the consequences of any actions taken. Observe the following precautions and instructions while working on the system: D Use a grounded wrist strap with a built-in one megohm resistor for your safety and to prevent damage to static sensitive circuits. The resistor allows static electricity to drain to ground and still isolates you from direct ground. Also use a grounded static mat. D Before removing or inserting any card (except a PeerWay buffer card) in a ControlFile, first disable the Nonvolatile Memory and then the secondary and then the primary Coordinator Processor cards. Only PeerWay Buffer cards may be changed with the Nonvolatile Memory and the Coordinator Processor cards active. D Turn off the Nonvolatile Memory Card before removing AC and DC power. D Always power down consoles before removing or installing console cards. D NOTE: The Disk Shutdown (DS) command should always be performed before powering down the console. This will purge the cache and prevent possible loss of data. When powering up the ControlFile, first enable the Nonvolatile Memory card and then enable the primary and then enable the secondary Coordinator Processor cards. All procedures assume that all red fault LEDs are corrected before proceeding to the Troubleshooting Tables. NOTE: Tap Box number 1984--0488--000x is the “A” PeerWay Tap Box. Tap Box number 1984--0489--000x is the “B” PeerWay Tap Box. The upper PeerWay Buffer and the upper connector on the back of the ControlFile belong to the “A” PeerWay. The lower PeerWay Buffer and lower connector on the back of the ControlFile belong to the “B” PeerWay. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-36 Diagnosing a Console or SCI PeerWay Problem - To diagnose a Console or SCI PeerWay problem: 1. Move the drop cable from one tap connection to another. CAUTION When moving drop cables and PeerWay buffers from a ControlFile for troubleshooting purposes, make certain you move only those associated with the suspect PeerWay. If anything on the good PeerWay is disconnected, the ControlFile or console could be taken off the PeerWay. Look at the PeerWay Node screen for this device, and note the “Noecho” and “Badecho” Fields. If the problem is now cleared, replace the Tap Box. If all tap connections are used, swap two drop cables at the Tap Box. Determine if the problem moved to the node that was swapped. If the problem moved, replace the Tap Box. 2. Replace the Console PeerWay Interface Card. 3. Replace the Console Power Regulator Card. 4. Replace the drop cable. 5. Command Console and Basic Command Console only: Pull the console card cage out and connect the drop cable directly to the back of the motherboard, bypassing the short marshaling panel cable. Use extreme caution when removing and installing the console card cage to avoid damaging any cables. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-37 Diagnosing a ControlFile PeerWay Problem The procedure for checking PeerWay problems differs according to the number of ControlFiles on the PeerWay. With One ControlFile on the PeerWay If there is only one ControlFile on the PeerWay, use the following procedure. - To diagnose a ControlFile PeerWay problem with one ControlFile on the PeerWay: 1. Move the drop cable from one tap connection to another. WARNING When moving drop cables and PeerWay buffers from a ControlFile for troubleshooting purposes, make certain you move only those associated with the suspect PeerWay. If anything on the good PeerWay is disconnected, the ControlFile or console could be taken off the PeerWay. Look at the PeerWay Node screen for this device, and note the “Noecho” and “Badecho” Fields on this screen. If the problem is now cleared, replace the Tap Box at the earliest convenience. If all of the tap connections are used, swap two drop cables at the Tap Box. Determine if the problem moved to the node that was swapped. If the problem moved, replace the Tap Box. 2. Remove the PeerWay Buffer card from the ControlFile on the faulty PeerWay. Follow step a or b below depending on the part number of the card. a. Part number 1984--1402--0003: The card must be replaced to determine if it is bad. If no spares are available, the card can be swapped with the other buffer in this cage. This will take the node off of the PeerWay. b. Part number 1984--1502--0001: Remove the card and move the seven jumpers (HD 2, 3, 4, 5, 6, 7, and 8) on the card to the TEST position. Install the card and look at the PeerWay Node screen and determine if the Noecho and Badecho Fields are at 0. If they are now at 0, the PeerWay Buffer Card is bad and must be replaced. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-38 WARNING If the Coordinator Processor Card is disabled on a running process, all operator process changes, links running between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controllers will continue to operate the process under these conditions. As soon as the Coordinator Processor Card is restarted all links will be updated. 3. Replace the Coordinator Processor Card. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-39 With Multiple ControlFiles on the PeerWay If there are several ControlFiles on the PeerWay, use the following procedure. - To diagnose a ControlFile PeerWay problem with multiple ControlFiles on the PeerWay: 1. Move the drop cable from one tap connection to another. WARNING When moving drop cables and PeerWay Buffer Cards from a ControlFile for troubleshooting purposes, make certain you move only those cards and cables associated with the suspect PeerWay. If anything on the good PeerWay is disconnected, the ControlFile could be taken off the PeerWay. 2. Look at the PeerWay Node screen from the Tap Box, and note the “Noecho” and “Badecho” Fields on the screen. If the problem is now cleared, replace the Tap Box at your earliest convenience. If all of the tap connections are used, swap two drop cables at the Tap Box. Determine if the problem moved to the node that was swapped. If the problem moved, replace the Tap Box. 3. Swap the PeerWay Buffer Card from this node’s bad PeerWay with a PeerWay Buffer Card from the same PeerWay of another ControlFile. If the problem moved, replace the PeerWay Buffer Card. WARNING If the Coordinator Processor Card is disabled on a running process, all operator process changes, links running between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controllers will continue to operate the process under these conditions. As soon as the Coordinator Processor Card is restarted all links will be updated. 4. If the problem does not move to the other ControlFile in step 3, replace the Coordinator Processor Card in the suspect card cage. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-40 PeerWay Cable Fault Diagnostics The pattern of error counts shown in Figure 10.2.11 is typical of an open PeerWay twinax cable. Note that the PeerWay Margin has been forced from 990 to 950 to see the pattern clearly. The Alarm “PeerWay A Problem,” the large total on PeerWay A, and the “Actual Margin” going toward 1000 all indicate that PeerWay A is bad. The pattern of Nodes 1, 2, and 4 is clearly separated from the rest of the node because these nodes are configured together (to indicate they are on the same Tap Box). The problem with the cable is on PeerWay A between the first two Tap Boxes. Pway >1 01 CLT 02 MC 04 MC 06 10 12 14 CC CTL MC MC 16 CC 32 MC PEERWAY OVERVIEW ®1 ®2 ®4 2 6 3 7 1 9 . . . . . . . . 8 2 6 . . . . . . . . . . ®6®10®12®14® 02-Apr-90 11:32:06 >scroll Left ®16®32® ® ® ® ® A B . . . . . . . . . . . . . . . . . . 715 742 633 0 0 0 ® 4 4 2 1 1 5 6 6 6 2 3 5 1 4 5 4 3 4 7 2 799 683 757 761 0 0 0 0 ® 3 9 2 2 3 6 5 6 673 787 0 0 4 10 8 4 1 6 3 8 ® ® ® ® ® ® ® --- ---Force Margin ®950 08:06:07 Actual Margin 950 PeerWay A Problem Idle 1296 786 20 CONFIG 3 Figure 10.2.11. Peerway Overview Screen (PeerWay A Problem) RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-41 Troubleshooting Twinax PeerWay Cables - To diagnose a twinax PeerWay cable problem: 1. Check all twinax cable connections for proper seating on the Tap Boxes. 2. Check that both ends of the PeerWay are properly terminated. 3. Check for multiple grounds. Only one Tap Box on each PeerWay (A and B) can have the jumper in the “SHIELD” position. 4. Check to make sure that all twinax cable connectors are isolated from ground. 5. Remove the “T” connector from the Tap Box, and keep the two twinax cables connected to the “T” connector. NOTE: The “Force Margin” field on the Peerway Overview screen should show “None”. Use an ohmmeter to measure the following resistances (see Figure 10.2.12 ): a. Between 1 and 2: 50 ohms nominal (acceptable range: 45 to 70 ohms). b. Between 1 and shield: resistance greater than 1 megohm. c. Between 2 and shield: resistance greater than 1 megohm. If the resistance between 1 and 2 is 100 ohms or greater (or in extended length cable, 124 ohms or greater), there is a break in one of the twinax cable segments. Disconnect the two twinax cables from the “T” and measure between 1 and 2 of both cable ends. The reading should be between 100 and 140 ohms. Follow the faulty cable back until the open is located. Terminations at both ends should read 100 or 124 ohms. If the resistance between 1 and shield or between 2 and shield measures less then 1 megohm, this indicates a short between one of the lines and the shield. Disconnect the two twinax cables from the “T” connector and measure each cable to find the faulty end. Continue following the cable segments until the fault is found. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-2-42 2 SHIELD 1 Figure 10.2.12. Twinax “T” Connector Troubleshooting Fiber Optic PeerWay Cables Optical PeerWay troubleshooting is more a technique than a process. The basic goal of the Fiber Optic Cable is to carry photo energy from the transmitting point to the receiving point with enough energy left for the receiver. Every element introduced into the optical path, such as splices, connectors, attenuators, star couplers, and the length of the fibers, reduces the amount of photo energy left for the receiver. The general process is to start from the transmitter and ensure the output is within acceptable limits (between --3 and --6.9 dbm). From the transmitter, work towards the receiver, taking measurements at each point along the way. If at any point a reading is not within the acceptable limits, take steps to remove the source of the problem. Possible causes include: D Improperly installed or dirty terminations. D Bends less than the minimum radius. D Cable lengths that exceed specifications. D A faulty Star Coupler, Tap Box, or repeater. As long as there is at least --33 dbm left at the receiver, the system should work. If it does not, the problem could be the receiver itself. See the Site Preparation and Installation Manual (SP) for troubleshooting procedures for fiber optic cables. RS3: Troubleshooting Troubleshooting a PeerWay SV: 10-3-1 Section 3: Troubleshooting Consoles This section covers troubleshooting problems with consoles, including: D General console troubleshooting procedures: — Console Power-Up Diagnostics — Console Off-Line Diagnostics — Console Crash Dump screen — Memory Dump — Memory View screen — Menu Confidence screen — Node Dump screen D Keyboard problems D CRT problems D Operator Interface (OI) Card Cage problems NOTE: Check for proper grounding of the Keyboard Interface Board. Improper grounding may lead to a variety of hard to trace symptoms. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-2 General Console Troubleshooting Procedures Use these procedures when a console passes its power-up diagnostics but will not boot up. - To diagnose Command Console problems: 1. Load from boot tape. If the console loads OK, replace the hard disk drive. NOTE: Use a tape made from the “Create Boot Tape” function. To load from tape, insert the boot tape and power-up the console. Hold [HDWR ALARM] throughout the Hardware Power Up Diagnostics screen until the console displays ”Loading from the Streaming Tape.” At the Main Menu, enter [DISK DIRECTORY PEERWAY], cursor to the “TAPE” field, and press [ENTER]. Run the “Restore Tape Files to Disk” function. Cycle DC power and try to load using the Winchester disk. If the console does not boot from disk, replace the disk drive assembly. NOTE: For the Enhanced or Standard Engineering Keyboard (1984--1654--000x): Hold the “H” key in place of [HDWR ALARM]. 2. If the console will not load from tape, replace the SCSI interface card. NOTE: Do not replace a Small Computer System Interface (SCSI) card with a Disk Interface card. - To diagnose MiniConsole problems: 1. Is the disk drive power LED red or off? 2. Is boot disk in drive 1 or 2 and is the disk drive latch closed? 3. Try the boot disk in the other drive. 4. Make sure the flat cable on the back of the motherboard is seated properly. 5. Try a different boot disk. If the console starts, put the original disk in the disk drive and press [CTL -- C] to reload the console configuration. 6. Install the Off Line Diagnostic disk and run the disk drive tests. 7. If the disk will not boot from either drive, replace the Floppy Disk Interface card. 8. Replace the disk drives. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-3 Console Power-Up Diagnostics When a console is powered up, the console is put through a series of comprehensive tests to verify console card operation. Figure 10.3.1 shows a Console Power Up Diagnostics screen. CC Console <Boot Version x.xx>...........................................PASSED Instruction Set Test ROM Test Four Meg RAM Test Bus/Interrupt Test Watch Dog Timer EDAC Test SR Test Video Generator..........................................................PASSED RAM Test PIT Test DAC Test Color Test Synch Test Keyboard.................................................................PASSED Display Panel 1.4 Trackball 1.4 Keyboard Interface 4.1 Option Panel 1.4 Option Panel 1.4 Option Panel 1.4 Power Supply.............................................................PASSED +5 +12 A: +30 B: +30 PeerWay..................................................................PASSED Register Check RAM Test #1 RAM Test #2 Jabber-Halt Local Loop Back Printer..................................................................PASSED RTC Periodic Interrupt NV RAM Test RTC Battery Printer Ready SCSI Board...............................................................PASSED DMA Registers RAM Test #1 RAM Test #2 SCSI Master SCSI Controller Winchester Tape Drive Figure 10.3.1. Console Power Up Diagnostics Screen If a failure occurs on a console card, the word “PASSED” is replaced with “FAILED” or “MISSING”. The console finishes the power-up tests, and puts an alarm at the bottom of the screen saying “CRITICAL FAULTY OR MISSING”. A card shown as “missing” has failed to the point that it cannot be detected in the card cage and the console will not run. If a card shows “FAILED,” the test it failed is backlit in red and the console may still be able to run, depending on the fault. Pressing [ACK] on the Loop Control Panel or the [ALARM ACK] button on the Operator Keyboard will attempt the system boot. Before pressing [ACK], note the card and the specific test it failed for future reference. NOTE: For the Enhanced Engineering Keyboard (1984--1654--000x): The red ACK key is not recognized until the console has finished booting. Press the “A” key or “F10” to acknowledge the alarm. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-4 NOTE: When a function such as redundant 30 VDC power is not connected, or a printer is not connected, they will be highlighted in blue. D D D A blue indication will not prevent a console from booting nor does it require the ACK keystroke to continue to boot. If the keyboard is missing, the console can still be booted. This feature is useful with the CRT function button, where one console can switch over to control another console. Blue highlighting indicates that: a. They did not pass diagnostics. b. They are not required for proper console operations. The diagnostic tests of the console cards are not dependent on one another, except for the Power Supply and Processor. These two cards are the minimum configuration required for testing. However, the Video Generator is necessary to get an indication of the keyboard test results. Table 10.3.1 shows a list of the tests. If a fault is indicated, operation may be questionable. Depending on the severity of the fault, it may be advisable to replace the card. Exceptions are indicated in the definitions of the tests listed in the table. Table 10.3.1. Console Power Up Tests Item Test Definition Console Processor Boot Version This number is the software revision of the ROM parts of the processor card. The ROM holds data to run the power-up diagnostics and the routine to load the Boot Disk into the console in order to begin operating. Instruction Set Test This tests the microprocessor. It runs an elaborate algorithm using varied instructions to verify the integrity of the microprocessor. A failure here means the processor may be bad. Replace the card. Also check Power regulator voltage. ROM Test A test of the integrity of the boot ROMs on the processor card that instruct the processor to run the power-up diagnostics. If a failure is indicated here and the acknowledge button starts the console, the failure will not affect operation of the console once it is running. Boot ROMs are only used during start up. The online test of the ROM (MCT Screen) may also mean test failures. Four Meg RAM Test An address and data test is run on the processor card RAM. If a failure is indicated here the console will probably not run reliably. NOTE: If a single bit error is detected during the RAM test, the Error Detection and Correction (EDAC) circuit will correct for a single RAM chip failure. The EDAC test is bypassed (shown by backlighting the EDAC test) and the console will not halt on this screen but will start up from disk in the normal way. A “Console Weak RAM Chip,bit XX” alarm is generated and put on the Active Alarm List. (continued on next page) RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-5 Table 10.3.1. Console Power Up Tests (continued) Item Test Definition Console (cont.) Bus/Interrupt Test This tests the processor card’s ability to talk to other cards on an interrupt level. A failure here may mean that the processor card is bad or one of the other cards in the console may be affecting the test. Turn off the power to the console and remove all cards but the power supply and processor. Remove the front panel keyboard cable. Turn on the console again and, after 30 seconds, the green LED on the processor card should turn on, indicating the card passed all tests. Add the rest of the cards one by one until the fault appears and replace that card. WatchDog Timer The watchdog circuit is allowed to time out and reset the microprocessor to verify its operation. The card will operate if the watchdog circuit is not functioning. Replace the card as soon as possible or, if a fault appears, the card may not reset in the case of a bad instruction. EDAC Test This tests the Error Detection and Correction circuitry. An error is written to RAM addresses to verify that the EDAC will correct it. If the card fails the EDAC test but passes the RAM test, there should be no fault that would corrupt data. The card should operate for a while but could reset the console frequently. Replace the processor card. SR Test Video Generator SRAM test. If a fault is indicated here, replace the card. RAM Test Addressing and data test of RAM in the Video Generator. Replace the card if a fault is shown. PIT Test Test of the Parallel Interface Timer, which is used to control interrupts. Replace the Video Generator card if a fault is shown. DAC Test Test of the Digital-to-Analog Converter, which measures voltages on the RGB output lines to the monitor. An error here can indicate that a video driver has failed so the card must be replaced. It could also indicate that the monitor is not properly terminated, the video cables are damaged, the shields are shorted to ground, or the type of cable is wrong. Color Test Tests for shorts between the RGB lines. An error could be a board fault or a cable fault. Synch Test Tests synch signal rates. Replace the Video Generator card if a fault is shown. (continued on next page) RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-6 Table 10.3.1. Console Power Up Tests (continued) Item Test Keyboard Lamps on for Visual Check TTY Keyboard Display Panel Power Supply PeerWay Definition All LEDs on the Loop Callup Panel are lit to verify they are working. This indicates that the null character was not received from the keyboard microprocessor by the console processor. A fault here could indicate a bad TTY Keyboard, a disconnected keyboard cable or a bad cable connection on the console motherboard. NOTE: If the cable between the motherboard and the Loop Callup Panel is disconnected, the console will show a fault but will still load the disk. The console screen then locks up showing the date, time, and an alarm at the bottom of the screen but with no menu. The panel is asked for the firmware revision number. The response is checked for correct format and checksum. The firmware level is displayed on the screen. If there is no response, the panel is assumed not installed. Trackball Same as Display panel. Keyboard Interface Same as Display panel. Option Panel Same as Display panel. +5V and +12V A voltage sense circuit is read and if the +5 or +12 volt supply on the power supply card is not in tolerance, the voltage will be backlit. Replace the power supply. A: +30 and B: +30 The voltage sense on the incoming DC bus is monitored and, if one of them is below approximately 18 volts, the indication will show a fault. Many consoles use only one DC bus for power so the card fault will not indicate “FAILED”. Register Check This is a check of the several chips on the card. If this test indicates a fault, replace the card. RAM Test #1 This is a data test of RAM on the card. Replace the card if a fault is indicated. RAM Test #2 This is an addressing test of the RAM. Replace the card if a fault is indicated. Jabber Halt A circuit on the card that keeps a faulty node from transmitting too long on the PeerWay. If this shows a fault, the card may operate, but should be replaced as soon as possible. Local Loop Back Tests the console’s ability to hear its own echo through the PeerWay. A failure means that the console is not working on one or both PeerWays. The Tap Box may be faulty, drop cables may be disconnected, or the PeerWay Interface card may be bad. (continued on next page) RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-7 Table 10.3.1. Console Power Up Tests (continued) Item Test Printer RTC SCSI Board (MTCC) Disk Drive (MC and BCC) Definition The operation of the Real Time Clock is tested. Replace the card if a fault is indicated. Periodic Interrupt This is a test of the interrupt system generated off the clock. Replace the card if a fault is indicated. NVRAM Test A checksum is run on the data in NVRAM. If the checksum is incorrect, the test will indicate a fault. The system will run if this is showing a fault, but some of the console configuration could be corrupt. Check the online NVRAM checksum test on the Menu Confidence Test screen. RTC Battery This shows the charge on the batteries that back up the Real Time Clock. If a fault shows, the battery charge is low or the battery jumper switch is in the off position. The battery status is monitored on the MCT screen. Printer Ready This shows if a printer is present and on line. If no printer is connected, it does not lock up the diagnostic screen, but backlights the printer indicator. Direct Memory Access (DMA) Registers Tests registers of several of the devices on the card to verify board operation. If a fault shows here, the console may not boot up from disk. If it does, operation can be attempted, but replace the card as soon as possible. RAM Test #1 This tests RAM on the Disk Interface card. Replace the card if a fault shows here. RAM Test #2 This is an addressing test of the RAM on the Disk Interface card. Replace the card if a fault is indicated. SCSI Master This indicates which console is the SCSI master. SCSI Controller Winchester This test checks the registers of the specialized SCSI interface bus devices for proper power up conditions. This test checks for disk ready signal, and verifies the integrity of several sections of the disk to make sure it works properly. NOTE: If the cable between the SCSI controller card located on the disk unit and the disk unit is not connected, both the disk and tape unit will indicate fault by being backlit in red. Tape Drive This test checks for the presence of the tape drive SCSI controller board and checks for tape ready signal. If no tape is installed the tape indication will be backlit blue. If a tape is present it will rewind the tape. NOTE: If the cable between SCSI controller card (located on the tape unit) and the tape unit is disconnected, this test will not indicate a fault unless a tape is installed. To verify this, install a tape in the unit. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-8 Console Off-Line Diagnostics Off-line diagnostics for the console are loaded from tape or floppy disk depending on the console in use. Tests are the same, with the exception of the keyboard tests, which are suited to the individual console. - To run the off-line diagnostics: 1. For a Command Console, insert the appropriate Off-Line Diagnostics tape in the console tape drive, turn the console power off for 30 seconds and then back on. Hold down the “Hardware Alarm” button during the power up diagnostics until the console indicates it is “Booting From Streaming Tape”. This boots the console and brings up the Off-Line Diagnostic Menu. For a MiniConsole or Basic Command Console, insert the appropriate Off-Line Diagnostics disk in either disk drive, turn off the console power for 30 seconds and then back on. This boots the console and brings up the Off-Line Diagnostic Menu. 2. Check the Power Up Diagnostic screen for any faults. 3. Run desired tests. Figure 10.3.2 shows the Off-Line Diagnostic Menu screen. Select the number of the desired test to execute the test. Table 10.3.2 defines the console tests. Revision No. X.xx OFF LINE DIAGNOSTIC MENU Processor Card 1. 2. 3. 4. Printer Interface Processor RAM Test Processor ROM Test Reset System - Power Up Test Processor SRAM Test Video Generator 9. 10. 11. 12. Color Video Video Alarm Keyboard Assemblies Palette RAM Test RAM Test Convergence Pattern Contacts Test SCSI Peripherals 22. 23. 24. 25. 26. 5. NVRAM Test 6. Clear NVRAM 7. Printer Port Loopback 8. Printer Barberpole Test Winchester Disk Exerciser Winchester Formatter Tape Tests Floppy Disk Exerciser Floppy Formatter 13. 14. 15. 16. 17. 18. 19. 20. 21. Command Entry Keyboard Test TTY/ASCII Keyboard Test Old TTY Cursor/Numeric Keys Test New TTY Cursor/Numeric Keys Test MTO Cursor/Numeric Keys Test Loop Callup Keyboard Test Trackball Keyboard Test Key Switch Test Panel Light Test PeerWay Interface Card 27. PeerWay Interface Card Test Enter Selection: Figure 10.3.2. Console Off Line Diagnostic Menu RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-9 Table 10.3.2. Console Off Line Diagnostic Menu Definitions Item Test Definition Revision No. Processor Card Printer Interface This indicates the software revision of the Off line Diagnostics test disk being used. 1. Processor RAM Test This is a thorough address and data test of all of the RAM on the card. The test takes approximately 4 minutes and will run indefinitely unless stopped by pressing the [CTL] and [C] buttons together (Control C function) or power to the MiniConsole is shut off. 2. Processor ROM Test A checksum test is run on the boot ROMs on the Processor card. The test is run very rapidly and will run indefinitely unless halted by a Control C function. 3. Reset System -Power-up Test This function will force the MiniConsole to go through the power-up test and reboot from disk. 4. Processor RAM Test This is a thorough address and data test of all of the SRAM on the card. 5. NVRAM Test This is a nondestructive test of the nonvolatile RAM on the Printer Interface card. The test must be allowed to run up to 8192 before the test is complete. Any write errors will be reported. 6. Clear NVRAM This is a destructive test of the nonvolatile RAM on the Printer Interface card. It will write all zeros to the NVRAM. Any write errors will be reported. The NVRAM must be reloaded from the disk Console Configuration file. 7. Printer Port Loopback Test This initiates a test of the circuitry to drive the printer. Before starting the test the Printer Interface card must be removed and jumpers HD 7, HD 8, and HD 9 must be moved to the test position and jumpers HD 1 through 6 should be removed. NOTE: All tests except the Printer Barber Pole test can be run with the jumpers in this position. Video Generator 8. Printer Barber Pole This test outputs a barber pole printer pattern for testing the printer. The printer must be set up for 9600 baud. 9. Color Palette RAM Test This tests the color palette. 10. Video RAM Test 16 pages can be written into the Video RAM. During the test, patterns are written to each page of the Video RAM. 11. Video Convergence Pattern This generates a test pattern to enable checking the CRT for alignment and linearity. No test results are given. 12. Alarm Contacts Test Tests the alarm contacts. (continued on next page) RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-10 Table 10.3.2. Console Off Line Diagnostic Menu Definitions (continued) Item Keyboard Assemblies Test Definition 13. Command Entry Keyboard Test This tests the Main Operator Keyboard Keys. All keys are pictured on the screen and each key picture will light when the corresponding key is pushed. 14. TTY/ASCII Keyboard Test This tests part of the individual TTY keys. All keys are pictured on the screen and each key picture will light when the corresponding key is pushed. 15. Old TTY Cursor/Numeric Keys Test This tests the Cursor/Numeric keys of the old configuration keyboard. 16. New TTY Cursor/Numeric Keys Test This tests the Cursor/Numeric keys of the new configuration keyboard. 17. MTO Cursor/Numeric Keys Test This tests the Cursor/Numeric keys of the enhanced keyboard. 18. Loop Callup Keyboard Test This tests the individual Loop Callup keys. All keys are pictured on the screen and each key picture will light when the corresponding key is pushed. 19. Trackball Keyboard Test This tests the trackball. 20. Keyswitch Test This tests the Key Switch. Each key can be inserted in the key switch and the key number that is seen by the system is reported on the screen. 21. Panel Light Test This test lights all the panel LEDs in single sequence and then in rows. It is used to verify all LEDs are working and no shorts exist between lights. (continued on next page) RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-11 Table 10.3.2. Console Off Line Diagnostic Menu Definitions (continued) Item Floppy Utilities Test Definition 22. Winchester Disk Exerciser This test reads and writes to the hard disk to determine if there is a hardware problem or a media problem. This test will destroy all information on the disk. 23. Winchester Formatter This test destroys all information on the disk and formats the disk. 24. Tape Tests This brings up a tape test menu that allows you to choose between the following tape drive tests: Retension Tape Erase Tape Tester/Exerciser Disk Copy Compare Tape Copy Unload Tape These tests can be used to test the tape drive. CAUTION: “Erase Tape” and “Tester/Exerciser” will destroy all information on the tape. PeerWay Interface Card 25. Floppy Disk Exerciser This test performs reads and writes to the floppy disk drive to determine if there are any drive problems. This test will destroy all information on the disk. 26. Floppy Formatter This test destroys all information on the disk and formats the disk. 27. PeerWay Interface Card test Runs these tests on the PeerWay Interface Card: RAM Test #1 RAM Test #2 Jabber-Halt Local Loop Back RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-12 Memory Dump The memory dump may help you diagnose software problems. A node’s RAM can be captured and viewed or saved to a file. The contents of RAM can often help solve difficult software problems. Disk event messages are generated as the result of memory dump activities. D D D - The memory dump can only be performed on consoles and CPs. The node must be active. If the PeerWay Node screen is functioning, the node is active. A memory dump can only be performed on 68020 consoles running Version 15 or higher. To make a memory dump of a node: 1. Cursor to the command line. Type: MD (node #) , (filename) [ENTER] 2. The memory of the specified node is put into the specified file in the Log Files folder. The file is of the type Memory Dump. The memory dump is performed in the background and may take a few minutes to complete. You can perform other tasks while the dump is occurring. - To stop a memory dump before it is finished: 1. Cursor to the command line. Type: KMD [ENTER] Automatic Controller Memory Dump Capture The automatic Controller Memory dump capture works as follows: D D D Memory Capture: In the event of a controller crash (at the point of the crash), the existing memory is copied to an unused portion of memory in the controller. The controller is rebooted, initializing all functional memory and variables to a restart state. You can check to see if there is a current memory dump in the controller by checking the “Node Dump” screen for the ControlFile node number and use the “Page Ahead” to view all dumps, noting the time and date. The captured memory image in the controller is stored in the upper area of memory. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-13 This captured memory will remain in the controller until: 1. The controller is rebooted using the front panel switch on the controller. <or> 2. Another controller crash or the “Snap Controller Memory” function overwrites the memory crash dump. The captured memory image from the controller can be downloaded to a console by using the standard “Memory Dump” command. This command is in the form: Command Keys: MD=[Node][Controller],[File Name] For example, to copy the controller captured memory to disk: Memory Dump: =1a,Dump1A will copy the capture from controller “=1A” to a file named “Dump1A”. Note that the command Memory Dump: =1,Dump1 will transfer the CP memory to the file. This is compatible with previous functionality. All Memory Dump file images will be placed in the “Log” folder of the console that initiated the Memory Dump command. The Memory Dump from a controller takes approximately 20 minutes to complete. Expected Memory Dump file size for the MPC2+ controller is 400 to 500 Kbytes in the LOG folder. The Disk Event List will report the Start time and Finish time of the Memory Dump. At this point, the memory dump can be viewed by using the Memory View function. Or you can copy the file to floppy disk or RS3 tape, and return it to FRSI for evaluation. If possible, please send a printout of the corresponding Node Dump along with the memory dump file. The Memory Dump command can be executed by the operator key level or above. Redundant controllers will store the Captured Memory, and allow a Memory Dump, but only if the controller that has captured the memory is active. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-14 With an A/B pair, for example: if A is running primary, and B is running secondary; and if the A controller crashes, the B controller will then be the active controller. (The memory dump is in the A controller, but the B controller is active.) An attempt at a “Memory Dump” at this point may show the error message: “No Dump found on this controller” (referring to the active B controller), or if there is a Memory Capture from a previous crash (or Memory Snap) in the B controller, then the B controller capture will be downloaded. To get the memory dump from the crashed controller, switch the active controller back to A. Other Commands There are several other commands that can be used along with the Memory Dump. 1. Kill Memory Dump (KMD) will abort any Memory Dump functions that are active for the console. Note that the Disk Event List will report that the Memory Dump “Finished”. There is no “Abort” entry given in the Disk Event List. Kill Memory Dump can be executed by the operator key level or above. 2. Snap Controller Memory command will initiate a manual controller memory capture. The command to execute this is “SC” followed by the “Next Option” key. The command is intentionally obscure to prevent unintentional use. CAUTION: The “Snap Controller Memory” command will freeze the control block and I/O execution for 2 seconds while the image is copied from the lower memory to the upper memory. Any sensitive blocks should be switched to manual. The main control disturbances will be caused by “derivative bump” on completion of the 2-second freeze. This function should be executed with care, while watching the process carefully. D D Snap Controller Memory command can be executed by the configuror key level or above. When the Snap Controller Memory command is entered, the message: ENTER again: causes 2-sec CONTROL FREEZE is displayed as a warning. You must press the Enter key again. D When the memory copy is complete the following message is displayed: DONE: ready for Memory Dump RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-15 Controller Memory Dump Recommendations D D RS3: Troubleshooting Should a controller crash occur, the memory dump should be done as soon as possible after the controller crashed, to save the image to disk. The file should be named to indicate the node and controller, and that it was a crash. If possible (note Caution above), after the controller image has been saved to disk, the “Snap Controller Memory” function should be run on the same controller and the subsequent image saved to disk. This second memory snap should be taken a day or so after the controller has crashed and recovered, to allow the internal memory stacks to begin to fill again to normal. (Although this second dump may be useful, it is not required.) The file should be named to indicate the node and controller, and that this is a normal operating image. This second image will be used by FRSI to compare the controller image for a normal operation. Troubleshooting Consoles SV: 10-3-16 Memory View Screen The Memory View screen allows you to view the contents of a memory dump file or the current contents of memory. The screen is only available with 68020 pixel consoles. Figure 10.3.3 shows an example of a Memory View screen. Table 10.3.3 describes the fields on the screen. - To read current memory data from a node: 1. Call up the Memory View screen. MV [ENTER] 2. If you want to look at a node other than the one you are at, change the “Node” field entry. - To read memory data from a file: 1. Call up the Memory View screen. MV [ENTER] 2. Cursor to the “Memory” field and press [ENTER]. The field changes to “File”. 3. Enter the “Volume”, “File Type”, and “Filename” of the file that contains the memory data. 4. Cursor to the “Read” field and press [ENTER]. 5. To access other screens to see more memory data: [PAGE AHEAD] and [PAGE BACK] RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-17 - To call up: D [M] [V] [ENTER] at the command line - To access other screens: D [PAGE AHEAD] and [PAGE BACK] to see more memory data Memory View 23-Oct-90 >Read ÞMemory >Hex View>byte Node>4 Addr 000: 010: 020: 030: 040: 050: 060: 070: 080: 090: 0A0: 0B0: 0C0: 0D0: 0E0: 0F0: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 CC 40 40 40 40 40 00 00 00 00 00 40 40 40 40 40 11:47:12 66 e7 e7 e7 e7 e7 67 67 6F 67 67 e7 e7 e7 e7 e7 >0000000000 66 12 12 12 12 12 1E A0 56 1E 1E 12 12 12 12 12 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 FF 40 40 40 40 40 00 50 00 00 00 40 40 40 40 40 00 E7 E7 E7 E7 E7 67 B5 6F 67 67 E7 E7 E7 E7 E7 00 12 12 12 12 12 46 DA 56 1E 1E 12 12 12 12 12 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 40 40 40 40 40 40 00 40 00 00 00 40 40 40 40 40 E7 E7 E7 E7 E7 E7 67 E1 67 67 66 E7 E7 E7 E7 E7 12 12 12 12 12 12 64 84 1E 1E EC 12 12 12 12 12 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 40 40 40 40 40 00 40 00 00 00 40 40 40 40 40 66 E7 E7 E7 E7 E7 67 E7 67 67 64 E7 E7 E7 E7 E7 F0 12 12 12 12 12 82 12 1E 1E 00 12 12 12 12 12 [email protected]. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. ..g...gF..gd..g. ..g..P...@...@. ..oV..oV..g...g. ..g...g...g...g. ..g...g...f...d. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. .@...@...@...@.. CONFIG 4 Figure 10.3.3. Memory View Screen RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-18 Table 10.3.3. Memory View Screen Field Description Description Field Addr Specifies the starting address of the memory data displayed on the screen. Decimal/Hex Specifies that addresses are shown in decimal or hexadecimal. To change this field, press [ENTER]. File/Memory Specifies that memory data is being read from a file or directly from the node. You can change this field by pressing [ENTER]. File Type Specifies the type of folder that contains the file you want to view. For memory dumps, the type should be “Log File”. Filename Specifies the name of the file that contains the memory data. Hex/Decimal See the “Decimal/Hex” field. Memory/File See the “File/Memory” field. Node Read Specifies the node number of the source of the memory data. Reads the current memory data onto the screen, or reads data from a file. Press [ENTER] to read new data. The Memory View screen takes a snapshot of memory. This field allows you to refresh the screen with the current contents of memory. Specifies how the data is interpreted and displayed. Byte =2 hex character groups Char =2 hex character groups View Float =Floating point numbers Link =Link addresses Long =8 hex character groups Short =4 hex character groups Time =System time Volume Specifies the name of the volume that contains the memory data file. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-19 Node Dump Screen The Node Dump screen shows details after a crash of a console or ControlFile. Enter ND nn where nn is the node number. Figure 10.3.4 shows an example of a node dump. This screen traps software errors, which may be caused by a faulty processor RAM or other hardware faults or software problems. NOTE: When power is removed, all crash node dump data is lost. Print out all pages of the node dump before cycling power. If you cannot get a screen printout, copy down all the items highlighted in the figure. D Screen Title D Time D Trap Number....SR Number....PC Number....Line Number D All of the lines of the System Stack, D All of the lines of the Registers Data D All of the lines of the User Stack It is also important to note which software revision levels are being run at the time of the crash. If the console locks up repeatedly, run Off-Line Diagnostics on the processor card ROM, disk or SCSI RAM, and Video Generator RAM. CONTROLFILE DUMP Crash XX-XXX-XX Trap Number:XXX 17-Apr-92 12:24:06 at XX:XX:XX of XXX XX Version XX.XX Node =XXX SR:XXXX PC:XXXXXXXX Line xxxx xx xxxx xxxxxx System Stack XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXX XXXX XXXX XXXX XXXX Registers XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX XX:XXXXXXXX User Stack XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX Figure 10.3.4. Node Dump Screen RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-20 Menu Confidence Screen The Menu Confidence screen displays console power status, the status or results of RAM and ROM tests, and the clock battery status. Enter MCT to call up the screen. You may boot the console by cursoring to “Power Up Test” and pressing [SELECT]. If the clock battery is bad or if its jumper is in the Off position, the status field will display a red “YES.” If the clock battery is good and its jumper is in the On position, the status field will display a “NO.” Figure 10.3.5 shows a Menu Confidence screen. BACKGROUND DIAGNOSTICS 01-Aug-91 Power Supplies Console Power Clock Battery +5v +12v Bus A Bus B Alarm GOOD GOOD GOOD BAD/UNUSED 09:25:03 NO +-------------------Background Test Results-------------------+ Pass Errors Processor RAM >2 0 Processor ROM >55445 0 Chip Code Startup Tune: >NONE >Power Up Test (press SELECT to start) WARNING: This will Clear Alarm Lists and Reboot the Station CONFIG 11 Figure 10.3.5. Menu Confidence Screen RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-21 Keyboard Problems A locked keyboard may be reset by holding down [CTRL], [ALT], and [INSERT] simultaneously. The console will report bad keys (shorted or excessive length keystroke) by the message “Keyboard Error X:XX” where the first X represents the keyboard number and the XX represents the key. The numbers for the keyboards keys depend on the type of console. See Alarm Messages (AL) manual for details. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-22 CRT Problems Figure 10.3.6 shows routing of the video signals. The Sync signals are superimposed on the green video signal. If the green cable is misconnected, there will be no picture. O/I Motherboard J082 -- RGB Color Video Output J081 -- Monochrome Video Output Video Marshaling Panel ··· ··· ··· Figure 10.3.6. Video Signal Routing If there are problems with the CRT, a quick way to test whether it is the monitor or the video source is to connect another monitor to the video cables. Another trick is to connect the video cables to another OI Card Cage. Figure 10.3.7 shows this reconnection technique. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-23 O/I Motherboard J082 -- RGB Color Video Output J081 -- Monochrome Video Output Video Marshaling Panel ··· ··· ··· Figure 10.3.7. Checking Video Signals RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-24 Troubleshooting OI Card Cage Problems NOTE: All procedures assume that you have found and corrected all red fault LEDs before going on to troubleshooting. The technique is to reduce the Operator Interface to a configuration that you know works. From that point, add removed components until you isolate the faulty component. CAUTION Remove power from the card cage each time a card is removed or inserted. Do not touch the gold edge connectors on any board. Replace any card that stops the progress of booting when it is installed. If this process does not find faulty components, contact FRSI for further assistance. - To diagnose a OI Card Cage problem: 1. Remove all Operator Interface card cage circuit boards except the Power Regulator. Put them on a grounded static mat. CAUTION Use a grounded wrist strap with a built-in one megohm resistor for your safety and to protect static sensitive circuits. The resistor allows static electricity to drain to ground and still isolates you from direct ground. 2. If the Power Regulator green LED comes on when power is applied, the Power Regulator is operational. 3. Install the OI Processor. At power-up, the red LED is on until the processor completes the self-diagnostics. When the green LED comes on, the Processor has passed all the power up diagnostics and is operational. 4. Install the Video Generator. Either the green or the red LED is on until the processor starts to run diagnostics on this board. While diagnostics run, the red LED is on. When the diagnostics are passed, the processor turns on the green LED. As soon as the Video Generator is installed, you can see the progress of the diagnostic tests on the screen. 5. Monitor the Console Power-Up screen for error indications. 6. Install the PeerWay Interface. Either the green or the red LED will be on until the processor starts to run the diagnostics. While diagnostics run, the red LED will be on. When the diagnostics are passed, the processor turns on the green LED. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-25 7. Install the Printer Interface. Either the green or the red LED will be on until the processor starts to run the diagnostics. While diagnostics run, the red LED is on. When the diagnostics are passed, the processor turns on the green LED. 8. Install the SCSI Host Adapter. Either the green or the red LED will be on until the processor starts to run the diagnostics on this board. While diagnostics are run, the red LED is on. When the diagnostics are passed, the processor turns on the green LED. CAUTION Before you put the console back into service, be sure to switch all the OI cages off. Switch them back on together to ensure that the proper cage becomes the SCSI Master. RS3: Troubleshooting Troubleshooting Consoles SV: 10-3-26 RS3: Troubleshooting Troubleshooting Consoles SV: 10-4-1 Section 4: Troubleshooting ControlFiles This section covers troubleshooting ControlFiles. All procedures assume that you have found all red fault LEDs and that they have been corrected first before proceeding to the troubleshooting process. The general procedure is to reduce the ControlFile to a configuration that you know works. From that point you can selectively add removed components until the faulty component is isolated. CAUTION Use a grounded wrist strap with a built-in one megohm resistor for your safety and the protection of static sensitive circuits. Do not touch the gold edge connectors on any board. Remove all ControlFile circuit boards except the Power Regulator, one Coordinator Processor, and the Nonvolatile Memory. If the green LED on the Power Regulator and the Coordinator Processor comes on when enabled, they should be considered operational. If the Coordinator Processor does not successfully boot, replace the Nonvolatile Memory, Coordinator Processor or the Power Regulator. The goal at this point is to have the ControlFile Coordinator Processor operating. Next install the the PeerWay Buffers. At this point you should be able to see the ControlFile Status on the console. CAUTION When performing this procedure care must be taken to disable the Nonvolatile Memory and then the Coordinator Processors each time a card is removed or inserted (with the exception of the PeerWay Buffer cards). Turn off the Nonvolatile Memory card before removing AC and DC power. Continue installing the other Power Regulator, the Coordinator Processor, and the Controller Processors one at a time until the faulty component is found. If, at any point, the installation of a circuit card stops the progress of Booting, that card should be replaced. NOTE: Any slot that previously contained a PLC, RBLC, or MUX Controller must have either a WIPE BUBBLE or KILL CONTROLLER done on it prior to loading an image or configuration. Failure to do so could cause some strange errors or problems with the controller. RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-2 Table 10.4.1 shows detailed procedures for troubleshooting ControlFiles. Table 10.4.1. ControlFile Troubleshooting Condition Controller Processor card will not pass Power Up Diagnostics. Action 1. Replace the Controller Processor card. Green LED does not come on. Controller Processor card will not start. The green LED comes on briefly with all yellow LEDs on. 1. The yellow LEDs on the Coordinator Processor and Nonvolatile Memory cards must be flickering, indicating that the cards are operating properly. NOTE: if no Controller Processor card is running inside this ControlFile, the Nonvolatile Memory card will have only a green LED on. If the Coordinator Processor and Nonvolatile Memory card LEDs are not as indicated, see section on “Coordinator Processor Will Not Load From Nonvolatile Memory”. 2. Perform a Wipe Bubble command on the suspect Controller Processor card. Re-enable the Controller Processor card after the Wipe Bubble procedure is performed. If the Controller Processor now starts, the plant Configuration must be reloaded from disk for that controller. Refer to the Wipe Bubble Procedure in this section. 3. Using a disk with the same software level as is in the ControlFile, perform a Disk Load Program command on that ControlFile. It is normal to have an active hardware alarm “Program Image Bad” for this node during the Disk Load Program function. The alarm must clear after the Disk Load Program is complete. If the Disk Load Program is successful, try to restart the Controller Processor card. 4. If the Controller Processor card has been jumpered for additional images, check the jumper positions on the card. See Chapter 4 of the this manual for jumper positions and locations. 5. Replace the Nonvolatile Memory card if the Disk Load Program is not successful. Then attempt the Nonvolatile Memory Recovery Procedure. (1) 6. Replace the Controller Processor card. 7. Replace the Coordinator Processor card. (1) (1) If a nonredundant Coordinator Processor card is disabled on a running process, all operator process changes, links between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controller will continue to operate the process under these conditions. As soon as the Coordinator Processor is restarted, all links will be updated. (2) If a Controller Processor card is disabled on a running process, the analog output Field interface card and the discrete output module will either hold their last value or go to zero, depending on the position of the jumper on the Field interface card. If it is necessary to close (go to zero) the output of the field device that uses the “HOLD” mode after the controller is disabled, the Field Interface card must be removed. (3) If both PeerWay Buffer cards are removed from the ControlFile on a running process, all operator changes and links to and from this ControlFile will freeze at the last value received. The links within the ControlFile will continue to update. The Controller Processors will continue to operate under these conditions. (continued on next page) RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-3 Table 10.4.1. ControlFile Troubleshooting (continued) Condition Action Controller Processor card will not start with the Coordinator Processor card in one of the two Coordinator Processor card slots. If the Coordinator Processor card is installed in the other slot, the controller will run. 1. Replace the Controller Processor card. 2. Replace the Coordinator Processor card. Controller Processor card will run alone, but: 1. Will not run as a redundant pair. 2. Either controller alone will start and run. 1. Check the Controller Processor cables on the back of the motherboard and verify that both the upper and lower cable connections for the two redundant Controller Processor slots are in place. 2. Ensure that both Controller Processors are seated properly inside the ControlFile. 3. Check the terminators on the back of the ControlFile motherboard 4. Replace the terminators. 3. Replace one Controller Processor at a time with a known good Controller Processor in redundant configuration. Coordinator Processor will not pass Power Up Diagnostics. The green LED does not come on and the top yellow LED is off. 1. Replace the Coordinator Processor card. (1) If a nonredundant Coordinator Processor card is disabled on a running process, all operator process changes, links between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controller will continue to operate the process under these conditions. As soon as the Coordinator Processor is restarted, all links will be updated. (2) If a Controller Processor card is disabled on a running process, the analog output Field interface card and the discrete output module will either hold their last value or go to zero, depending on the position of the jumper on the Field interface card. If it is necessary to close (go to zero) the output of the field device that uses the “HOLD” mode after the controller is disabled, the Field Interface card must be removed. (3) If both PeerWay Buffer cards are removed from the ControlFile on a running process, all operator changes and links to and from this ControlFile will freeze at the last value received. The links within the ControlFile will continue to update. The Controller Processors will continue to operate under these conditions. (continued on next page) RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-4 Table 10.4.1. ControlFile Troubleshooting (continued) Condition Coordinator Processor will not load from the Nonvolatile Memory card. The green LED comes on briefly, then the red FAULT LED comes on. The top yellow LED is on. Action 1. Check that the Nonvolatile Memory card switch is in the ENABLE position. 2. Check that the Nonvolatile Memory card is in the proper slot within the ControlFile. (See diagram on ControlFile door.) NOTE: If the primary Coordinator Processor is running and the secondary is not, the primary should NOT be disabled at this time. An attempt should be made to load the Plant Program into the nonvolatile memory (Disk Load Program function). If the function fails the Nonvolatile Memory card must be replaced. (1) 3. Move the Coordinator Processor card to its redundant slot. If the Coordinator Processor works in the redundant slot, see the Troubleshooting section on “Coordinator Processor Will Not Start In One Of The Two Slots”. 4. Replace the Nonvolatile Memory card. NOTE: The Nonvolatile Memory Recovery Procedure may help recover the card if it is bad. The PeerWay Boot Procedure is also available. 5. Replace the Coordinator Processor card. 6. Check that ControlFile motherboard terminators are installed correctly. NOTE: If no Controller Processors were running, the plant configuration must be reloaded from disk. (1) If a nonredundant Coordinator Processor card is disabled on a running process, all operator process changes, links between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controller will continue to operate the process under these conditions. As soon as the Coordinator Processor is restarted, all links will be updated. (2) If a Controller Processor card is disabled on a running process, the analog output Field interface card and the discrete output module will either hold their last value or go to zero, depending on the position of the jumper on the Field interface card. If it is necessary to close (go to zero) the output of the field device that uses the “HOLD” mode after the controller is disabled, the Field Interface card must be removed. (3) If both PeerWay Buffer cards are removed from the ControlFile on a running process, all operator changes and links to and from this ControlFile will freeze at the last value received. The links within the ControlFile will continue to update. The Controller Processors will continue to operate under these conditions. (continued on next page) RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-5 Table 10.4.1. ControlFile Troubleshooting (continued) Coordinator Processor starts but stops after a short period of time. ControlFile appears on the ControlFile Status screen and then disappears. 1. Pull out the two PeerWay Buffer cards in the ControlFile. (3) 2. Reseat the Coordinator Processor and Nonvolatile Memory cards and try to restart the Coordinator Processor. 3. If the Coordinator Processor now starts and runs, check the Control Block Directory screens (a configuration key must be used when viewing the screens) of all other ControlFiles on the PeerWay for corrupted data. Look for scrambled loop tags and abnormal block status and dynamic memory sizes. 4. If a suspect controller is located, the Kill Controller function must be performed on all Controller Processors in that cage.(2) After the Kill Controller has been performed, the plant configuration must be reloaded from the disk to the ControlFile. 5. With the PeerWay Buffers cards still removed, disable and remove all Controller Processor cards within the faulty cage. (2) 6. Reseat the Coordinator Processor and Nonvolatile Memory cards and try to start just these two cards. If the Coordinator Processor will not stay running, replace it. 7. If the Coordinator Processor now starts and runs, begin installing the Controller Processor cards one at a time. As each card is installed, restart the Coordinator Processor and Controller Processor cards (this is done to determine if one of the Controller Processors is preventing the Coordinator Processor from running). 8. If a Controller Processor is found that prevents the Coordinator Processor from running, reseat and start the Coordinator Processor and Nonvolatile Memory cards with all Controller Processors set to DISABLE. After the Coordinator Processor is running, reinstall the PeerWay Buffer cards and perform the Wipe Bubble command for all Controller Processors in the ControlFile. 9. Turn all Controller Processors to ENABLE and allow them to restart. If one of the Controller Processors will not start, or if it will not allow the Coordinator Processor to start, replace that Controller Processor card. 10.After the ControlFile is running with all of its Controller Processors, load the Plant Configuration from disk for that ControlFile. (1) If a nonredundant Coordinator Processor card is disabled on a running process, all operator process changes, links between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controller will continue to operate the process under these conditions. As soon as the Coordinator Processor is restarted, all links will be updated. (2) If a Controller Processor card is disabled on a running process, the analog output Field interface card and the discrete output module will either hold their last value or go to zero, depending on the position of the jumper on the Field interface card. If it is necessary to close (go to zero) the output of the field device that uses the “HOLD” mode after the controller is disabled, the Field Interface card must be removed. (3) If both PeerWay Buffer cards are removed from the ControlFile on a running process, all operator changes and links to and from this ControlFile will freeze at the last value received. The links within the ControlFile will continue to update. The Controller Processors will continue to operate under these conditions. (continued on next page) RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-6 Table 10.4.1. ControlFile Troubleshooting (continued) Condition Action Coordinator Processor card will not start in one of the two Coordinator Processor slots, but will start and run in the other slot. 1. Remove (1) (2) (3) all cards in the ControlFile except for one Power Regulator card, one Nonvolatile Memory card, and one Coordinator Processor card in the faulty slot. Re-enable the Coordinator Processor and Nonvolatile Memory cards. If the Coordinator Processor now runs, proceed to step 5. 2. If the Coordinator Processor does not start, replace the Nonvolatile Memory card. 3. If the Coordinator Processor still does not start, replace the Power Regulator card. 4. If the Coordinator Processor still will not run in this slot, check the ControlFile terminators on the back of the ControlFile card cage. 5. Once the Coordinator Processor is running in this minimum configuration, install the remaining cards one at a time until the card is found that prevents the Coordinator Processor from running. Replace the faulty card. Coordinator Processors will run separately, but not as a redundant pair. 1. Replace the Nonvolatile Memory card. 2. Replace the Coordinator Processor cards one at a time. 3. Check the ControlFile terminators on the back of the ControlFile card cage. (1) If a nonredundant Coordinator Processor card is disabled on a running process, all operator process changes, links between controllers in that cage, and links to and from that ControlFile will freeze at the last value received. The controller will continue to operate the process under these conditions. As soon as the Coordinator Processor is restarted, all links will be updated. (2) If a Controller Processor card is disabled on a running process, the analog output Field interface card and the discrete output module will either hold their last value or go to zero, depending on the position of the jumper on the Field interface card. If it is necessary to close (go to zero) the output of the field device that uses the “HOLD” mode after the controller is disabled, the Field Interface card must be removed. (3) If both PeerWay Buffer cards are removed from the ControlFile on a running process, all operator changes and links to and from this ControlFile will freeze at the last value received. The links within the ControlFile will continue to update. The Controller Processors will continue to operate under these conditions. RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-7 ControlFile Status Screen Figure 10.4.1 shows the ControlFile Status screen. The ControlFile Status screen is where you can find out what program type (such as $$CP, $$CPMax, or $$CPBat) and version level is loaded in the CP boards. The Coordinator Processor and Controller Processor must be booted to determine what $$CP program and version is loaded in the NV Memory. You can find the Image type and the version level for each controller card on this screen by reading the “Card Type” Field, and the “Prgm Rev” fields for each Controller card. Also, you can tell what additional images are loaded in the NV Memory by the “Additional Images” fields, but you cannot tell what level of each Image is loaded in the NV Memory. The Jumper Code field indicates MPC II or MPC5 functionality and image selection as determined by jumpers on the card. Displayed as X_Y_Z where: X = MPC II HD2 setting: 0 for MPC I functionality 1 for MPC II functionality Y = combination of HD6, HD7, and HD8 as an octal number Z = combination of HD4, HD5, and HD9 as an octal number See the writeup on the CP card for jumper details and the Control Block Manual (CB) for a complete description of this screen. RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-8 CONTROL FILE STATUS 07-Aug-98 15:34:12 Node Address >1 File Status >Stdby Batch CP Batch Config NVM 128 K Left CP: Boot 4.03 Prgm P1.09 Avail Links 39 Idle Time 45. % Right CP: Boot 4.03 Left Program NVM Free 32. % BRAM V1.16 Soft Count 0 Additional Images: 1. MPC2+ Config NVM Free 328 K +--------------- A --- B --- C --- D --- E --- F --- G --- H Alarm MPC+ 6.05 P1.11 95. % 96. % 76 4600 Alarm MPC+ 6.05 P1.11 47. % 54. % 69 4554 MPC+ 6.05 P1.11 86. % 98. % 77 4554 PLC+ 6.05 P1.11 97. % 99. % 77 4600 ®Norm ®no ®no ®Norm ®no ®no ®Norm ®no ®no >Stdby ®no ®no 1_7_7 1_7_7 1_7_7 1_7_6 SC Time Out ÞNone ÞNone ÞNone ÞNone Scan time NV Mem Used Þ1. S 8 K Þ1. S 32 K Þ.25 S 8 K Þ1. S 8 K Control Type Boot Rev Prgm Rev Idle Time Free Space Avail Links Avl Trnd Spc Primary Status Alarm Inhib Start Cal Start Cal Jumper Code Figure 10.4.1. ControlFile Status Screen RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-9 Wipe Bubble Procedure The following procedure describes how to perform a Wipe Bubble procedure on the ControlFile Nonvolatile Memory. Wiping rewrites the header and purges the plant configuration information for the specified Controller Processor card. The command works on Bubble NV Memory and RAM NV Memory. CAUTION When a Wipe Bubble or a Kill Controller procedure is performed on an MPC I controller, all *ENTRY and *VALUE items will be lost. Write down the values BEFORE wiping the configuration. When a Wipe Bubble or a Kill Controller procedure is performed on a MUX configuration the calibration constant of the FEMs will be lost. The calibration constants should be written on the FEM. - To wipe the NV memory: 1. Toggle the desired Controller Processor card enable/disable switch to DISABLE. 2. Move the cursor to the command line and press: WB = [Controller Processor address] An alarm is generated: BUBBLE WIPED FOR CONTROLLER=xx The NV memory is now wiped. 3. Toggle the Controller Processor card enable/disable switch to ENABLE. RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-4-10 RS3: Troubleshooting Troubleshooting ControlFiles SV: 10-5-1 Section 5: Troubleshooting Input/Output This section covers I/O troubleshooting: D General I/O problems D Analog Card Cages D FlexTerms D Field Interface cards D Rosemount Basic Language (RBL) controller and cards These procedures assume that you have found and corrected all red fault LEDs before you going on to troubleshooting. CAUTION Use a grounded wrist strap with a built-in one megohm resistor for your safety and to protect static-sensitive circuits. Place all cards on a grounded static mat or in a static protection envelope. Potential problem areas include: D Bad fuses (in and out -- no indicators) D Bad card D Bad Controller card D Bad cable D Bad software D Bad firmware D Bad I/O Block or ControlBlock configuration D Bad field device CAUTION Remove power from the Multiplexer FlexTerm before installing or removing any cards. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-2 Restoring Redundant FICs When a primary Field Interface Card (FIC) with redundancy fails, the redundant FIC takes over. The failed FIC lights its red LED or flashes its green LED. Replace the failed FIC and determine that the new FIC has its green LED lighted and that the FIC Status screen shows no error for the FIC. The “Health” field of the primary FIC will still show “Bad”. Restore the original configuration to make redundancy effective. WARNING Do not pull the redundant FIC to force a switch back to the primary FIC. This introduces a “double hardware failure” and may result in unexpected operation. - To restore FIC redundancy: 1. Call up the Redundant input/Output Block (RIOB) screen. 2. Put the RIOB in MANUAL. 3. Highlight the line: Reset Backup of Line n (Press [ENTER]) and press [ENTER]. This restores the primary FIC and resets the backup FIC for backup action. The Health field of the primary FIC will now show “Good”. 4. Put the RIOB in AUTO. Normal redundancy operation is restored. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-3 Troubleshooting Procedures for Serial Input/Output Serial I/O is often called “MPC I/O”. See: D Table 10.5.1 for serial I/O D Table 10.5.2 for Multiplexer (MUX) I/O D Table 10.5.3 for Resistance Temperature Detector (RTD) and Thermocouple I/O Table 10.5.1. Serial (MPC) I/O Troubleshooting Condition Analog Input No Reading Inst. Low Alarm AIB Field Reading -25% Action 1. Use a VOM to check that the input current is in the range 4--20 mA. If a transfer card is installed, measure between test points on the card. Otherwise, measure at the marshaling panel by breaking the loop. If the current is OK: Check the FlexTerm to ControlFile cables. Replace the FIC. Replace the Controller Processor Card. If the current is not OK: Check all fuses on the FIC. 2. Using the RMT 262 Field calibrator (or similar device), input an appropriate current signal into the marshaling panel. If the value is wrong on the AIB screen, replace the FIC. If the value is correct on the AIB screen, check the field wiring and the transmitter. Be sure to check the system/self-powered jumper on the FIC. Analog Input shows incorrect or unstable reading. 1. Using the RMT 262 Field Calibrator (or similar device), input an appropriate current signal into the marshaling panel. Check the Field Reading on the AIB screen. If the reading is incorrect: Calibrate the point. Replace the FIC. Replace the Controller Processor Card. If the reading is correct: Measure the transmitter current with the RMT 262 (or similar device). Check the field wiring for shorts and resistance to ground. (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-4 Table 10.5.1. Serial (MPC) I/O Troubleshooting (continued) Condition Analog output Feedback check alarm Action 1. Remove the field wiring from the marshaling panel for this FIC. Connect a Rosemount 262 Field Calibrator (or similar device) to the terminals. Put the AOB in MANUAL and enter an output value of 50.00%. Check the Actual Value reading on the AOB (it should be 50%) and verify that the Rosemount 262 meter reading is also 50% (12 mA). 2. If the Actual Value Reading and the meter reading are not 50%: Check all fuses on the output FIC. Calibrate the point. Replace the FIC. Replace the controller. 3. If the Actual Value and meter readings are 50% and the alarm clears off the Active Hardware Alarm List, the problem is an open circuit in the field wiring or the field device. Discrete input module does not work. Input FIC point LED not on. FIC communications are OK. 1. Check the mode of the Contact Input Block (CIB); it must be in AUTO or MANUAL. If the Status Field is blank, this indicates an override condition, which is illegal for a CIB. Check if the discrete manual bypass is turned on for this point. Replace the FIC. Replace the FlexTerm motherboard. 2. Measure the voltage across the input terminations for the faulty point. NOTE: If the CIB is configured for Normally Closed (N.C.) operation, the Field State on the CIB screen will show ON when the module has no voltage across it and OFF when the module has voltage across it. 3. If no voltage is present across the point: Check the polarity for the DC module. Replace the module. Replace the FIC. 4. If all of the points on this FIC and the card next to it are not working, the FIC may not be seated properly in its connectors. It is possible one of the two connector tabs are not seated correctly in the FlexTerm motherboard connectors. WARNING Before proceeding, remove all field voltage from the FIC to prevent shock or equipment damage. Loosen the two captive screws holding the FIC in place. Gently move the card away from the FlexTerm mounting plate and verify that both card connector tabs are properly plugged into the motherboard connectors. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-5 Table 10.5.2. Multiplex I/O Troubleshooting Condition Action Multiplex input point(s) bad. 1. Put an appropriate substitute signal into the point. Verify the accuracy to determine if the problem is system or field related. CAUTION Always remove field DC power before working on a 4 -- 20 mA input Front End Module (FEM). NOTE: Do not remove or insert FEMs with power on. If the problem is in the system: a. For thermocouples, check the configuration of the MIB. Verify that the “SIG CHAR” field is not configured for millivolts (example: J NBS is correct; do not use NBS mV). NOTE: J = type J thermocouple NBS = National Bureau of Standards b. For 4--20 mA inputs with the 10 ohm dropping resistors mounted on the marshaling panel, remove the field wiring and measure the resistance of the resistor. c. Replace the FEM. 2. Remove the input signal from the FEM. Configure the MIB for “Raw Counts”. The MIB input reading should be about 20000. If it is much lower, replace the FEM. MIB I/O Block configuration shows FEM type The FEM may have been inserted with MUX power ON. Turn MUX power OFF and then ON to force the MUX CPU to reinitialize. “None Type C”. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-6 Table 10.5.3. RTD and Thermocouple I/O Troubleshooting Condition Action RTD and thermocouple field problems. For RTD and thermocouple field problems, check the following items carefully: Loose or corroded connections or FEM not securely mounted in MUX. This can cause all input points to read as negative numbers. For FEM mounting instructions see SV: 5--3. Reverse polarity Wires shorted to case at temperature sensor Wrong type of thermocouple wire Noise caused by close proximity to AC wires High common node voltage. Measure from all device leads to chassis with a digital voltmeter using both AC and DC meter scales. Universal Voltage FEM shows positive overload on open circuit. This appears when Universal Voltage FEM is connected through a remote communication link and configured as a thermocouple input. The system cannot differentiate between a thermocouple with a high temperature reading and one with a broken or open loop. Check that the MUX CPU PROM is Doric (Beckman) part number 278--7000--03B. Communication failure to MUX CPU and the Coordinator Processor. Ensure that TransZorbs CR17 through CR20 are bipolar (PGKE47CA). The correct units have no polarity marking. Low thermocouple reading (or reading at low value) for thermocouples attached to Universal FEM. Incorrect RTD readings with two or three-wire RTDs. TC/RTD FIC shows poor accuracy. This appears when MIB is configured for TC or mV input. Replace the FEM. 1. Check for correct wiring at FEM. 2. Check for correct wiring at RTD Marshaling Panel and at FEM. If the sensor of an 1984--2731--000x TC/RTD FIC is disconnected and reconnected, the reading will be inaccurate for approximately 10 minutes. The reading will be within 1% in one minute and will gradually gain accuracy. This is a characteristic of the circuit. (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-7 Table 10.5.3. RTD and Thermocouple I/O Troubleshooting (continued) Condition Action Discrete output module does not work. FIC communications are OK. 1. Put the COB into MANUAL Status and command the output to ON. Verify that the output LED for the FIC is on. The proper load must be connected. 2. If the LED is on: Check the module fuse. Check the field voltage. Replace the module. If the LED is not on: Replace the module Replace the FIC NOTE: Output Modules ODC5A5 and OAC5A5 are Normally Closed (N.C.) Modules. 3. If all points on this FIC and the FIC next to it are not working, the FIC may not be seated properly in its connectors. It is possible one of the two connector tabs is not seated correctly in the FlexTerm motherboard connectors. WARNING Before proceeding, remove all field voltage from the FlexTerm Termination card to prevent shock or equipment damage. Loosen the two captive screws holding the FIC in place. Gently move the card away from the FlexTerm mounting plate and verify that both card connector tabs are plugged into the motherboard connectors properly. Discrete output module does not work. FIC communications are OK. 1. Put the COB into MANUAL Status and command the output to ON. Verify that the output LED for the FIC is on. The proper load must be connected. 2. If the LED is on: Check the module fuse. Check the field voltage. Replace the module. If the LED is not on: Replace the module Replace the FIC NOTE: Output Modules ODC5A5 and OAC5A5 are Normally Closed (N.C.) Modules. 3. If all points on this FIC and the FIC next to it are not working, the FIC may not be seated properly in its connectors. It is possible one of the two connector tabs is not seated correctly in the FlexTerm motherboard connectors. WARNING Before proceeding, remove all field voltage from the FlexTerm Termination card to prevent shock or equipment damage. Loosen the two captive screws holding the FIC in place. Gently move the card away from the FlexTerm mounting plate and verify that both card connector tabs are plugged into the motherboard connectors properly. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-8 Troubleshooting Procedures for Analog Input/Output The tables below give detailed troubleshooting procedures for analog I/O. See: D Table 10.5.4 for Analog I/O D Table 10.5.5 for MUX I/O. D Table 10.5.6 for RTD and Thermocouple I/O. Table 10.5.4. Analog I/O Troubleshooting Condition Action Analog Input No Reading 1. For each input, measure between test point 1 and 2 for 4 mA current at 1 volt. For 20 mA the voltage should be 5 volts. a. If the voltage is OK: Inst. Low Alarm AIB Field Reading -25% Check the FlexTerm to ControlFile cables. Replace the Controller Processor Card. 2. If the voltage is not OK, pull the FIC and check all fuses. Using the RMT 262 Field calibrator (or similar device) input an appropriate current signal into the Field Termination board. a. If the signal does not read properly, replace the FIC. b. If the signal does read properly, check the field wiring and the transmitter. Be sure to check the system/self-powered jumper on the FIC. Analog Input shows incorrect or unstable reading. 1. Using the RMT 262 Field Calibrator (or similar device), input an appropriate current signal into the Field Termination board. Check the Field Reading on the AIB screen. a. If the reading is incorrect: Replace the FIC. Replace the Controller Processor Card. b. If the reading is correct: Measure the transmitter current with the RMT 262 (or similar device). Check the field wiring for shorts and resistance to ground. (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-9 Table 10.5.4. Analog I/O Troubleshooting (continued) Condition Analog output Feedback check alarm Action 1. Remove the field wiring from the Field Termination Panel for this Field Interface Card. Connect a Rosemount 262 Field Calibrator (or similar device) to the terminals. Put the AOB in MANUAL and Enter an output value of 50.00%. Check the Actual Value reading on the AOB (it should be 50%) and verify that the Rosemount 262 meter reading is also 50% (12 mA). 2. If the Actual Value Reading and the meter reading are not 50%: a. Check all fuses on the output FIC. b. Replace the FIC. c. Replace the controller. 3. If the Actual Value and meter readings are 50% and the alarm clears off the Active Hardware Alarm List, the problem is an open circuit in the field wiring or the field device. Discrete input module does not work. Input FIC point LED not on. FIC communications are OK. 1. Check the mode of the CIB; it must be in AUTO or MANUAL. If the Status Field is blank, this indicates an override condition, which is illegal for a CIB. a. Check if the discrete manual bypass is turned on for this point. b. Replace the FIC. c. Replace the FlexTerm motherboard. 2. Measure the voltage across the input terminations for the faulty point. NOTE: If the CIB is configured for Normally Closed (N.C.) operation, the Field State on the CIB screen will show ON when the module has no voltage across it and OFF when the module has voltage across it. 3. If no voltage is present across the point: a. Check the polarity for the DC module. b. Replace the module. c. Replace the FIC. 4. If all points on this FIC and the card next to it are not working, the Field Termination card may not be seated properly in its connectors. It is possible one of the two connector tabs is not seated correctly in the FlexTerm motherboard connectors. CAUTION Before proceeding, remove all field voltage from the FIC to prevent shock or equipment damage. Loosen the two captive screws holding the Field Termination Card in place. Gently move the card away from the FlexTerm mounting plate and verify that both card connector tabs are plugged into the motherboard connectors properly. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-10 Table 10.5.5. Analog I/O MUX Troubleshooting Condition Action Multiplex input point(s) bad. 1. Put an appropriate substitute signal into the point. Verify the accuracy to determine if the problem is system or field related. CAUTION Always remove field DC power before working on a 4 -- 20 mA input Front End Module (FEM). NOTE: Do not remove or insert FEMs with power on. If the problem is in the system: a. For thermocouples, check the configuration of the MIB. Verify that the “SIG CHAR” field is not configured for millivolts (example: J NBS is correct; do not use NBS mV). b. For 4--20 mA inputs with the 10 ohm dropping resistors mounted on the marshaling panel, remove the field wiring and measure the resistance of the resistor. c. Replace the (FEM). MIB I/O Block configuration shows FEM type The FEM may have been inserted with MUX power ON. Turn MUX power OFF and then ON to force the MUX CPU to reinitialize. “None Type C”. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-11 Table 10.5.6. Analog I/O RTD and Thermocouple Troubleshooting Condition Action RTD and thermocouple field problems. For RTD and thermocouple field problems, check the following items carefully: 1. Loose or corroded connections or FEM not securely mounted in MUX. This can cause all input points to read as a negative number. For FEM mounting instructions see SV: 5--3. 2. Reverse polarity 3. Wires shorted to case at temperature sensor 4. Wrong type of thermocouple wire 5. Noise caused by close proximity to AC wires 6. High common node voltage. Measure from all device leads to chassis with a digital voltmeter using both AC and DC meter scales. Universal Voltage FEM shows positive overload on open circuit. This occurs if a Universal Voltage FEM is connected through a remote communication link and configured as a thermocouple input. The system cannot differentiate between a thermocouple with a high temperature reading and one with a broken or open loop. Check that the MUX CPU PROM is Doric (Beckman) part number 278--7000--03B. Communication failure to MUX CPU and the Coordinator Processor. Ensure that TransZorbs CR17 through CR20 are bipolar (PGKE47CA). The correct components have no polarity marking. Low thermocouple reading (or reading at low value) for thermocouples attached to Universal This appears when MIB is configured for TC or mV input. Replace the FEM. FEM. Incorrect RTD readings with two or three-wire RTDs. 1. Check for correct wiring at FEM. 2. Check for correct wiring at RTD Marshaling Panel and at FEM. (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-12 Table 10.5.6. Analog I/O RTD and Thermocouple Troubleshooting (continued) Condition Action TC/RTD FIC shows poor accuracy. If the sensor of an 1984--2731--000x TC/RTD FIC is disconnected and reconnected, the reading will be inaccurate for approximately 10 minutes. The reading will be within 1% in one minute and will gradually gain accuracy. This is a characteristic of the circuit. Discrete output module does not work. FIC communications are OK. 1. Put the COB into MANUAL Status and command the output to ON. Verify that the output LED for the FIC is on. The proper load must be connected. 2. If the LED is on: a. Check the module fuse. b. Check the field voltage. c. Replace the module. If the LED is not on: d. Replace the module e. Replace the FIC NOTE: Output Modules ODC5A5 and OAC5A5 are Normally Closed Modules. 3. If all points on this FIC and the FIC next to it are not working, the Field Termination Card may not be seated properly in its connectors. It is possible one of the two connector tabs is not seated correctly in the FlexTerm motherboard connectors. CAUTION Before proceeding, remove all field voltage from the FlexTerm Termination card to prevent shock or equipment damage. Loosen the two captive screws holding the Field Termination Card in place. Gently move the card away from the FlexTerm mounting plate and verify that both card connector tabs are plugged into the motherboard connectors properly. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-13 Field I/O Status Screen (FIC Status Screen) The Field I/O Status Screen (previously FIC Status screen) displays information about the Field Interface Cards (FICs) and Field interface Modules (FIMs) that communicate with a Controller Processor. This screen is for display purposes only. No screen entries are allowed. To call up the Field I/O Status screen, type the command FS [=address] [ENTER] where “address” is the hardware address such as =87F. NOTE: MultiLoop FlexTerms, some Contact FlexTerms, and Multiplexor FlexTerms cannot be displayed on this screen. Figure 10.5.1 shows the Field I/O Status screen. Table 10.5.7 describes the Field I/O Status screen fields. Table 10.5.7 covers the status bits. Bit 0 of the status field is the rightmost bit, bit 7 is the leftmost. Cont =87F FIELD I/O STATUS 1 2 3 23-May-95 4 5 6 16:01:49 7 8 A Type F-Rev S-Rev Status AIO-R 1.0 2.0 00000101 AIO-R AIO-R AIO-R AIO-R AIO-R AIO-R 1.0 1.0 1.0 1.0 1.0 1.0 2.0 2.0 2.0 2.0 2.0 2.0 00000101 00000101 NON-BOOT 00000101 00000101 0000010 AIO-R 1.0 2.0 00000101 B Type F-Rev S-Rev Status AIO-R 1.0 2.0 00000101 AIO-R AIO-R AIO-R AIO-R AIO-R AIO-R 1.0 1.0 1.0 1.0 1.0 1.0 2.0 2.0 2.0 2.0 2.0 2.0 00000101 00000101 NON-BOOT 00000101 00000101 0000010 AIO-R 1.0 2.0 00000101 C Type None F-Rev S-Rev Status None None None None None None None D Type None F-Rev S-Rev Status None None None None None None None Figure 10.5.1. Field I/O Status Screen RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-14 Table 10.5.7. Field I/O Status Screen Fields Description of Displayed Information Field Cont 1 2 3 4 5 6 7 8 A, B, C, D Address of the Controller Processor in the ControlFile. Communication Line from the Controller. The column below shows what is connected to the communication line. Card Cage address. Configured type of FIC. When the type is changed, this is displayed in the corresponding alarm color. AO AIO AIO_R AIO_RS Type CIO DIO MAI MAI32--x MAO PIOB SI TIB Early analog output card Analog I/O (2 in 1 out or 3 in FIC with all programs in ROM) Redundant Analog I/O (2 in 1 out or 3 in FIC with redundancy and downloadable code in battery backed RAM) Redundant Analog I/O with Smart daughterboard (2 in 1 out or 3 in FIC with redundancy, downloadable code in battery backed RAM, and a Smart daughterboard for HART communication) Contact I/O (six points per card) Discrete I/O (32 point discrete input/output FIM) Multipoint Analog Input (16 point Input FIM) Multipoint Analog 32 Point Input. (32 point input FIM) “x” shows cage address of the “other” 16 points. Multipoint Analog Output (16 point output FIM) Pulse input/output FIC HART input card Temperature input FIC F-Rev Revision level and firmware of the FIC. S-Rev Revision level of the FIC software. Status Displays the status of the FIC. Refer to the next table for a list and description of the status bits that may appear. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-15 Table 10.5.8. FIC/FIM Status Bits Status for: Status Bits Any NONBOOT Analog FIC Bits: 1xxx xxxx 7 Lost calibration: Set to 1 if any A/D or D/A calibration constants become questionable. x1xx xxxx 6 A/D converter failure. Set to 1 if any A/D converter does not complete a conversion within 45 milliseconds. xx1x xxxx 5 Smart Transmitter message available. Set to 1 when a message is available. xxx1 xxxx 4 Redundancy Jumper. Set to 1 for 1:1 redundancy. Set to 0 for other redundancy (including none). xxxx 1xxx 3 Output Bypass Unit status. Set to 1 when the Output Bypass Unit is active. xxxx x1xx 2 Hold/Zero jumper setting. Set to 1 to hold output value if a problem occurs. xxxx xx1x 1 Normal/Inverse acting valve jumper setting. Set to 1 for inverse acting valves. xxxx xxx1 0 Background diagnostics failure. Set to 1 if any background diagnostic test (except calibration constants) fails. 1xxx xxxx 7 Indicates the health of the other FIM. Set to 1 if the other FIM is “sick” or missing. x1xx xxxx 6 Set to 1 if this FIM is disconnected from the field. xx1x xxxx 5 Indicates the health of this FIM. Set to 1 if this FIM is “sick”. xxx1 xxxx 4 xxxx 1xxx 3 Not currently used. Always set to 0. (Early versions reported DC power status with this bit.) xxxx x1xx 2 Loop Power Module status bits: 0 for Loop Power Module A. 1 for Loop Power Module B. xxxx xx1x 1 Set to 0 when the Loop Power Module is good. Set to 1 when there is a problem with the Loop Power Module. xxxx xxx1 0 Set to 0 when the Loop Power Module is present. Set to 1 when the Loop Power Module is absent. Analog FIM Bits: Bit Description Indicates that the FIC/FIM program needs to be loaded. Input Data Validity; Set to 0 if the data is good. Set to 1 if the data is invalid. Output Data Validity: This bit is not used for outputs. (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-16 Table 10.5.8. FIC/FIM Status Bits (continued) Status for: Status Bits Bit Contact Bits: 1xxx xxxx 7 Setting of the Hold jumper: 1 = Hold, 0 = Off x1xx xxxx 6 Diagnostics: 1 = Fault, 0 = OK xx1x xxxx 5 Point 6 when the OBU is connected: 1 = Normal, 0 = Override xxx1 xxxx 4 Point 5 when the OBU is connected xxxx 1xxx 3 Point 4 when the OBU is connected xxxx x1xx 2 Point 3 when the OBU is connected xxxx xx1x 1 Point 2 when the OBU is connected xxxx xxx1 0 Point 1 when the OBU is connected 1xxx xxxx 7 RAM test result: Set to 1 if the RAM background test fails. x1xx xxxx 6 ROM test result: Set to 1 if the ROM checksum fails. xx1x xxxx 5 CPU test result: Set to 1 if the CPU test fails. xxx1 xxxx 4 Redundancy status: Set to 1 for 1:1 redundancy; set to 0 for any other redundancy (including none). 3 Not used. xxxx x1xx 2 D/A failure: Set to 1 when the D/A has failed three times in a row. xxxx xx1x 1 Open loop: Set to 1 if analog output is open circuit. xxxx xxx1 0 General diagnostic status: Set to 1 if any diagnostic test fails. Pulse Bits: xxxx 1xxx Description (continued on next page) RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-17 Table 10.5.8. FIC/FIM Status Bits (continued) Status for: Status Bits Bit Temp Bits: 1xxx xxxx 7 Lost calibration: Set to 1 if any A/D calibration constant becomes questionable. x1xx xxxx 6 A/D Converter failure. xx1x xxxx 5 Not used. xxx1 xxxx 4 Redundancy Jumper setting. 3 Not used. xxxx x1xx 2 Not used. xxxx xx1x 1 Not used. xxxx xxx1 0 General diagnostic status: Set to 1 if any background diagnostic test fails. 1xxx xxxx 7 Health of the other FIM: Set to 1 when the other FIM is bad or is not present. x1xx xxxx 6 Disconnect bit: Set to 1 when the other FIM has been disconnected by this FIM. xx1x xxxx 5 Configuration bit: Set to 1 when there is a problem with the configuration of this FIM. xxx1 xxxx 4 A/D #4: Set to 1 when there is a problem with A/D group 4 (points 25--32). xxxx 1xxx 3 A/D #3: Set to 1 when there is a problem with A/D group 4 (points 17--24). xxxx x1xx 2 A/D #2: Set to 1 when there is a problem with A/D group 4 (points 9--16). xxxx xx1x 1 A/D #1: Set to 1 when there is a problem with A/D group 4 (points 1--8). xxxx xxx1 0 Overall test: Set to 1 if any test fails. xxxx 1xxx Discrete I/O FIM Bits: RS3: Troubleshooting Description Troubleshooting Input/Output SV: 10-5-18 FIC Detail Screen The FIC Detail screen displays information about the blocks that are associated with an individual FIC or FIM. This screen is for display purposes only. To call up the FIC Detail screen, cursor to the desired FIC or FIM and press [SELECT] from the FIC Status screen. To view the FIC Detail screen for a FIC or FIM, cursor to the desired card and press [SELECT]. If any I/O Block is in alarm, the associated FIC or FIM will be in a corresponding color. Figure 10.5.2 shows the FIC Detail screen. Table 10.5.9 describes the FIC Detail screen fields. FIC DETAIL Controller FIC Type DIO Tag/Address =33CA101 =33CA102 =33CA103 =33CA104 =33CA105 =33CA106 A1 =33C 23-May-95 16:01:49 F-Rev 1.0 S-Rev 2.0 Status ssssssss aaaaaaaa bbbbbbbb cccccccc dddddddd Type SIB SIB AOB DOB DOB DOB . . . Value 00 00 00 Mode MANUAL MANUAL AUTO AUTO AUTO AUTO Figure 10.5.2. FIC Detail Screen RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-19 Table 10.5.9. FIC/FIM Detail Screen Fields Field Description of Displayed Information Controller Address of the Controller Processor associated with the particular FICs. None is displayed if no Controller Processor has been assigned. Type Configured type of FIC: analog I/O (AIO), contact I/O (CIO), redundant analog I/O (AIO-R), redundant AIO with Smart daughterboard (AIO-RS), discrete I/O (DIO). When the type is changed, this is displayed in the corresponding alarm color. FIC Slot number of the FIC within the Controller Processor. F-Rev Revision level and firmware of the FIC. S-Rev Revision level of the FIC software. Status Displays the status of the FIC. Tag/Address Tag or address of the FICs residing in the Controller Processor. Type Type of block on the FIC. Value Output value of the block. Mode Mode of the FIC: AUTO, MANUAL, or SIMULATE. There are five groups of status bits: D ssssssss Same as the FIC/FIM status bits shown in Table 10.5.8 D aaaaaaaa Status bits for points 1 to 4 D bbbbbbbb Status bits for points 5 to 8 D cccccccc Status bits for points 9 to 12 D dddddddd Status bits for points 12 to 16 Status bits a, b, c, and d apply only to Multipoint Analog and Multipoint Discrete I/O (MAIO and MDIO). Bit 0 of the status field is the rightmost bit, bit 7 is the leftmost. Table 10.5.10 shows the meaning of these bits. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-20 Table 10.5.10. FIC/FIM Status Bits Status Bits Bit 1xxx xxxx 7 Not used. Multipoint x1xx xxxx 6 Not used. Discrete xx1x xxxx 5 Input Latch for points 25--32: Set to 1 if bad. I/O xxx1 xxxx 4 Input Latch for points 17--24: Set to 1 if bad. FIM xxxx 1xxx 3 Input Latch for points 9--16: Set to 1 if bad. (MDIO) xxxx x1xx 2 Input Latch for points 1--8: Set to 1 if bad. xxxx xx1x 1 Output Latch for points 9--16: Set to 1 if bad. xxxx xxx1 0 Output Latch for points 1--8: Set to 1 if bad. 1xxx xxxx 7 Overall health of point 4, 8, 12, or 16 Multipoint x1xx xxxx 6 Calibration Constant condition of point 4, 8, 12, or 16 Analog xx1x xxxx 5 Overall health of point 3, 7, 11, or 15 Input xxx1 xxxx 4 Calibration Constant condition for point 3, 7, 11, or 15 FIM xxxx 1xxx 3 Overall health of point 2, 6, 10, or 14 (MAI) xxxx x1xx 2 Calibration Constant condition for point 2, 6, 10, or 14 xxxx xx1x 1 Overall health of point 1, 5, 9, or 13 xxxx xxx1 0 Calibration Constant condition for point 1, 5, 9, or 13 1xxx xxxx 7 Feedback check for point 4, 8, 12, or 16 Multipoint x1xx xxxx 6 Calibration Constant condition for point 4, 8, 12, or 16 Analog xx1x xxxx 5 Feedback check of the point for point 3, 7, 11, or 15 Output xxx1 xxxx 4 Calibration Constant condition for point 3, 7, 11, or 15 FIM xxxx 1xxx 3 Feedback check for point 2, 6, 10, or 14 (MAO) xxxx x1xx 2 Calibration Constant condition for point 2, 6, 10, or 14 xxxx xx1x 1 Feedback check for point 1, 5, 9, or 13 xxxx xxx1 0 Calibration Constant condition for point 1, 5, 9, or 13 Status for: RS3: Troubleshooting Description Troubleshooting Input/Output SV: 10-5-21 RBL Controller and Cards See Chapter 2 of the Rosemount Basic Language Manual (RB) for a test program that checks the entire RBL Controller and output cards. RS3: Troubleshooting Troubleshooting Input/Output SV: 10-5-22 RS3: Troubleshooting Troubleshooting Input/Output SV: 10-6-1 Section 6: Troubleshooting PeerWay Interface Devices This section covers troubleshooting of PeerWay Interface devices. OI Bubble Memory Problems If an OI Bubble Memory (1984--1167--000x or 1984--1147--000x) loses the program Image or will not start the OI Processor, the bubble may be corrupted. The procedure does not apply to an OI RAM NV Memory card (1984--1547--000x). Devices covered are: D Supervisory Computer Interface (SCI) D Highway Interface Adapter (HIA) D Diogenes Interface (DIO) D Rosemount Factory Interface (RFI) The program image resides within the PeerWay I/F folder on a console disk. The device must be able to communicate on the PeerWay in order to download the program from the disk. The problem is: 1. The OI Processor must be able to communicate over the PeerWay in order to download a new program from the disk. 2. The OI Processor must boot from a good OI Bubble NV Memory card in order to communicate over the PeerWay. 3. The OI Bubble NV Memory card is bad. The procedure to be used requires having a good OI Bubble NV Memory card for use. It may be borrowed from another PeerWay interface device (a card from an HIA may be used in an SRU). The software levels must be part of the same release: V11.xx is not compatible with V9.xx. Check with the FRSI Systems Support Group if you are uncertain about the software levels involved. RS3: Troubleshooting Troubleshooting PeerWay Interface Devices SV: 10-6-2 - To restore the OI Bubble NV Memory: 1. Turn off the power on the card cage with the problem and remove the failed OI Bubble NV Memory card. 2. Check to be sure that jumper HD19 (in the upper center portion of the board) is in the “NORMAL” position. Reinstall the card in the normal (left hand) slot. 3. Set jumper HD19 of the good board to “DOWNLOAD”. With the jumper in this position the bubble is a “read-only memory”. Install the good card in the slot to the right of the bad card. 4. Turn on the card cage power. The OI Processor will perform self-diagnostics and check the cards in the cage. When it tries to check the failed OI Bubble NV Memory card the test will fail. The Processor will then use the second (good) card to load the program. When this is completed, the device will be an active node on the PeerWay and will be able to communicate. 5. At a console, use Disk Directory PeerWay (DDP): a. Select the Disk Volume that contains the PeerWay Interface program folder. b. Open the folder and cursor to the required interface program ($$DIOxxx, $$HIAxxx, $$RFIxxx, or $$SCIxxx). c. Press [ENTER], which calls up the Disk Activity screen. d. Cursor to the Operation field. Use [NEXT OPTION] and [ENTER] to select “Disk Load PeerWay I/F Program”. e. Cursor to the Node field and enter the node number of the device with the problem. f. Cursor to “Press <Enter> to begin”, and press [ENTER]. This loads the program to the bad bubble card. The good bubble will not be affected since it is in a “read-only” state. g. Acknowledge the “Bubble Program Image Bad” alarm. Monitor the Disk Event List to determine the success of the download operation. 6. Turn off the power on the card cage with the problem and remove the good OI Bubble NV Memory card. Put jumper HD19 in the “NORMAL” position and return the card to its original place. 7. Turn on the card cage power. The OI Processor should boot from the restored OI Bubble Memory card and operate normally. If it does not do so, try the procedure again. If it still fails, the OI Bubble Memory card is bad and must be replaced. RS3: Troubleshooting Troubleshooting PeerWay Interface Devices RS3t Service Manual Appendixes Appendix A: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B: IEC and ISO Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Appendix C: Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 RS3: Appendixes Contents SV: ii List of Tables Table RS3: Appendixes Page A.1 Fuses Used in the RS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 B.1 IEC and ISO Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Contents SV: A-1 Appendix A: Fuses Table A.1 shows the fuses used in RS3. The FRSI part number is given first along with the equivalent fuse part number from Bussman, Littelfuse, Schurter, or Wickman. Table A.1. Fuses Used in the RS3 FRSI Bussman Littelfuse Schurter Wickman Characteristics G09140-0010 AGC 1/4 312.250 1/4 A 250 V Quick Acting 0011 MDQ 1/4 313.250 1/4 A 250 V Slow Blow 0016 AGC 1/2 312.500 .5 A 250 V Quick Acting 0017 MDQ 1/2 -- -- .5 A 250 V Slow Blow 0023 MDQ 1 313001 1 A 250 V Slow Blow 0029 MDQ--1-1/2 31301.5 1.5 A 250 V Slow Blow 0030 AGC 2 312002 2 A 250 V Quick Acting 0032 MDL 2 313002 2 A 250 V Slow Blow 0034 AGC 3 312003 3 A 250 V Regular 0036 MDL 3 313003 3 A 250 V Slow Blow 0037 AGC 4 311004 4 A 32 V Regular 0038 MDL 4 313004 4 A 250V Slow Blow 0039 AGC 5 311005 5 A 32 V Regular 0041 MDL 5 312005 5 A 250 V Regular 0044 AGC 7-1/2 31107.5 7.5 A 32 V Regular 0045 AGC 8 -- -- 8 A 250 V Regular 0046 AGC 10 311010 10 A 32 V Regular 0047 AGC 15 311015 15 A 32 V Regular 0060 MTH 4 312004 4 A 250 V Regular (continued on next page) RS3: Appendixes Fuses SV: A-2 Table A.1. Fuses Used in the RS3 (continued) FRSI Bussman Littelfuse 0061 ABC 20 314020 20 A 250 V Regular 312010 10 A 250 V Quick Acting 0062 Schurter Wickman Characteristics 0064 GMC5 G09149-0022 AGC 1 312001 G50382-0009 -- -- 273.125 MSF 034.4210 1/8 A 125 V Plug-In 0011 273.250 MSF 034.4213 1/4 A 125 V Plug-In 0014 273.500 MSF 034.4216 1/2 A 125 V Plug-In 0021 273002 MSF 034.4224 2 A 125 V Plug-In G50527-0004 ---- 5 A 250 V Regular 1 A 250 V Quick Acting SLC50 50 A 300 V Time Delay G53394-0250--5 Series 216 Series 19194 .25 A 125 V (IEC) 127--2 Fast Acting 5x20 mm 1000--1 Series 235 Series 19197 1.0 A 250 V CSA approved 1000--5 216 001 19 194 1A 1.0 A 250 V (IEC) Quick action 5x20 mm Ceramic 3000--1 Series 235 Series 19197 3.0 A 250 V CSA approved 3150--5 216 3.15 19 194 3.15 A 3.15 A 250 V (IEC) Quick action 5x20 mm Ceramic G10802-0007 MCR 1 251001 1A 125 V MST 250 50P0398 0007 RS3: Appendixes SC-30 19372K 3.15 A, 250 V Slow Blow, Plug-In 30 A 300 V Time Delay Fuses SV: B-1 Appendix B: IEC and ISO Symbols Table B.1 describes the International Electrotechnical Commission (IEC) and International Organization for Standardization (ISO) symbols used in this manual. Table B.1. IEC and ISO Symbols Symbol l RS3: Appendixes Publication Description IEC 417, No. 5031 Direct current IEC 417, No. 5032 Alternating current IEC 417, No. 5033 Both direct and alternating current IEC 417, No. 5017 Earth Ground TERMINAL IEC 417, No. 5019 Protective Conductor TERMINAL IEC 417, No. 5020 Frame or Chassis TERMINAL IEC 417, No. 5021 Equipotentiality IEC 417, No. 5007 On (Supply) IEC 417, No. 5008 Off (Supply) IEC 417, No. 5172 Equipment protected throughout by DOUBLE INSULATION or REINFORCED INSULATION ISO 3864, No. B.3.6 Caution: Risk of electric shock ISO 3864, No. B.3.1 Caution: Refer to accompanying documents IEC 417, No. 5041 Caution: Hot surface IEC 27--1, No. 101a Power Factor IEC and ISO Symbols SV: B-2 RS3: Appendixes IEC and ISO Symbols SV: C-1 Appendix C: Acronyms and Abbreviations A A Ampere AC Alternating Current A/D Analog to Digital ADLC Advanced Data Link Controller AIB Analog Input Block AIO Analog Input/Output AIO-R Redundant Analog Input/Output AIO-RS Redundant Analog Input/Output with Smart Daughterboard Amp Ampere ANSI American National Standards Institute AOB Analog Output Block ARB Arbitration ASCII American Standard Code for Information Interchange A.S.H.R.A.E. American Society of Heating, Refrigeration, and Air Conditioning Engineers ASIC Application Specific Integrated Circuit ASYNC Asynchronous AUI Attachment Unit Interface AWG American Wire Gauge B BCC Basic Command Console BCD Binary-Coded Decimal BMI Buffered Motherboard Interface BNC Baby “N” Connector BRAM Battery Backed Random Access Memory BTU British Thermal Unit RS3: Appendixes Acronyms and Abbreviations SV: C-2 C C Celcius CC Command Console; Contact Controller CE Conformité Européenne (Marking that indicates compliance to all applicable European directives) CENELEC European Committee for Electrotechnical Standardization CFM Cubic Feet per Minute CFS ControlFile Status (an RS3 command line entry) CH Chassis CIB Contact Input Block CIO Contact Input/Output CJC Cold-Junction Compensator cm Centimeter(s) cm3 Cubic Centimeters CMOS Complementary Metal-Oxide Semiconductor COB Contact Output Block Com. Common CP Coordinator Processor cpi Characters Per Inch CPLST Coodinator Processor Line Status cps Characters Per Second CPU Central Processing Unit CRC Cyclical Redundancy Check CRT Cathode-Ray Tube CSA Canadian Standards Association (Canadian Approval) CTS Clear to Send D D/A Digital to Analog DAC Digital-to-Analog Converter dB Decibel dBm Decibels above (or below) 1 Milliwatt DC Direct Current DCD Data Carrier Detect DCE Data Circuit-Terminating Equipment DCS Distributed Control System RS3: Appendixes Acronyms and Abbreviations SV: C-3 DDP Disk Directory PeerWay DEC Digital Equipment Corporation DIB Discrete Input Block DIN Deutsche Industrie Normenausschuss (a German national standards organization) DIO Discrete Input/Output DIP Dual Inline Package DMA Direct Memory Access DMAC Direct Memory Access Controller DNB Data Terminal Not Busy DOB Discrete Output Block DRAM Dynamic Random Access Memory DS Disk Shutdown (an RS3 command line entry) DSR Data Set Ready DTE Data Terminal Equipment DTACK Data Transfer Acknowledge DTR Data Terminal Ready DUART Dual Universal Asynchronous Receiver/Transmitter DVM Digital Voltage Meter E ECC Enhanced Command Console EDAC Error Detection and Correction EEPROM Electrically Erasable Programmable Read-Only Memory EEROM Electrically Erasable Read-Only Memory EIA Electronic Industries Association EMC Electromagnetic Compatability EMI Electromagnetic Interface EN European Norm EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge ETS Electrical Tap Set F F Fahrenheit FEM Front End Module RS3: Appendixes Acronyms and Abbreviations SV: C-4 FET Field Effect Transistor FIC Field Interface Card FIM Field Interface Module FMS Flexible Media Stack FO Fiber Optic FRSI Fisher-Rosemount Systems, Inc. FSA Formatter/Sense Amplifier ft Feet G g Acceleration of gravity at Earth’s surface GAK Gate Array Logic GND Ground H HARTR Highway Addressable Remote Transducer (HARTR is a registered trademark of the HART Communication Foundation) HCC Hardened Command Console HIA Highway Interface Adapter HOB HART Output Block hr Hour HVAC Heating, Ventilation, and Air Conditioning Hz Hertz I ID Identification i.e. Id Est (that is) IEEE Institute of Electrical and Electronics Engineers I/F Interface IGND Isolated Ground in. Inch(es) I/O Input/Output IP International Protection IP Internet Protocol I/P Current to Pressure IS Intrinsic Safety RS3: Appendixes Acronyms and Abbreviations SV: C-5 ISA Instrument Society of America ISO Isolated IT Isolation Transformer J K Kb Kilobit (1024 bits) KB Kilobyte (1024 bytes) KBI Keyboard Interface Card kg Kilogram kHz Kilohertz km Kilometer KMD Kill Memory Dump kVa Kilovolt-ampere KVI Keyboard/Video Interface L LAN Local Area Network lb Pound(s) lbf Pounds of Force LED Light Emitting Diode LFD Line Fault Detection LLB Local Loop Back lpi Lines Per Inch LPM Loop Power Module LVD Low Voltage Directive M m Meter(s) m3 Cubic Meters mA Milliampere MAC Media Access Control MAIO Multipoint Analog Input/Output MB Megabyte MBM Magnetic Bubble Memory MC MiniConsole RS3: Appendixes Acronyms and Abbreviations SV: C-6 MDIO Multipoint Discrete Input/Output MDIOH Multipoint Discrete Input/Output -- High-Side Switch FIM MDIOL Multipoint Discrete Input/Output -- Low-Side Switch FIM MEG Megabyte MHz Megahertz MIB Multiplexer Input Block MIO Multipoint Input/Output mm Millimeter MLC MultiLoop Card MMI Main Memory Interface MOS Metal-Oxide Semiconductor MP Marshaling Panel MPC MultiPurpose Controller ms Millisecond MTBF Mean Time Between Failure(s) MTCC Multitube Command Console MTL Measurement Technologies Limited MTO Master Terminal Operator MUX Multiplexer mV Millivolt(s) mV/m Milivolt(s) per meter N N/A Not Applicable NBS National Bureau of Standards (American) -- This organization is now known as the National Institute of Science and Technology. N.C. Normally Closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association nm Nanometer(s) NSm Newton Meter(s) No. Number N.O. Normally Open NRTL Nationally Recognized Testing Laboratory (American) NRTL/C Nationally Recognized Testing Laboratory/Canada (meets American and Canadian standards) RS3: Appendixes Acronyms and Abbreviations SV: C-7 NRZ Non-Return to Zero NV Nonvolatile NVRAM Nonvolatile Random Access Memory O OBC Output Bypass Card OBU Output Bypass Unit OEM Original Equipment Manufacturer OI Operator Interface OSC Oscillator OTS Optical Tap Set P PAL Programmable Array Logic PIOB Pulse Input/Output Block PIT Parallel Interface Timer PLC Programmable Logic Controller PLCB Programmable Logic Controller Block PLD Programmable Logic Device P/N Part Number ppm Parts Per Million psi Pounds per Square Inch PTM Programmable Timer Module PVC Polyvinyl Chloride PWA Printed Wiring Assembly PWB Printed Wiring Board PX PeerWay Extender Q QBI QBUS to PeerWay Interface R RAM Random Access Memory RBL Rosemount Basic Language RBLC Rosemount Basic Language Controller RCVR Receiver RS3: Appendixes Acronyms and Abbreviations SV: C-8 RF Radio Frequency RFI Rosemount Factory Interface RGB Red-Green-Blue RGRANT Redundancy Grant RIOB Redundant Input/Output Block RMON Remote Monitoring RMP RS3 Millennium Package rms Root Mean Square RNI RS3 Network Interface ROM Read Only Memory ROS RS3 Operator Station RREQ Redundancy Request RSEL Redundancy Select RTC Real Time Clock RTD Resistance Temperature Detector RTN Return RTS Ready to Send RX Receive RXC Receive Clock RXD Data Receive S SAMA Scientific Apparatus Makers Association SCI Supervisory Computer Interface SCR Silicon-Controlled Rectifier SCSI Small Computer System Interface SEL Selector SELV Separated Extra-Low Voltage SH Shield SIB Smart Transmitter Input Block SMS System Manager Station SNMP Simple Network Management Protocol SRAM Static Random Access Memory SRU System Resource Unit SSC Single-Strategy Controller SSR Solid State Relay RS3: Appendixes Acronyms and Abbreviations SV: C-9 S/W Software SYNC Synchronous T TB Termination Board TC Thermocouple TEA Transfer Error Acknowledge TI Texas Instruments TIB Temperature Input Block TIC Time Interval Controller TIL Technical Information and Library Services TTL Transistor to Transistor Logic TTY Teletypewriter TX Transmit TXMT Transmitter TXC Transmit Clock TXD Data Transmit U UART Universal Asynchronous Receiver/Transmitter UDH Unit Data Highway UL Underwriters Laboratories UPS Uninterruptible Power Supply V V Volt(s) VA Volts Ampere VAC Volt(s) Alternating Current VAX Virtual Address Extension (a DEC family of computers) VDC Volt(s) Direct Current VI Volts Isolated VIB Value Input Block V/m Volts per meter RS3: Appendixes Acronyms and Abbreviations SV: C-10 W W Watt(s) WAN Wide Area Network X XMTR Transmitter RS3: Appendixes Acronyms and Abbreviations SV: Index-1 RS3t Service Manual Index Numbers 1012 V0 0444 AA, 6-6-11 1022 A0 0242 AA, 6-6-11 1026 A0 0242 AA, 6-6-11 1032 H0 0242 AA, 6-6-11 1034 H0 0242 AA, 6-6-11 1072 D3 0510 AA, 6-6-11 1072 F3 0510 AA, 6-6-11 10P 5037000x, 6-6-14 50400006, 4-3-2 50450001, 3-7-10 5049000x, 6-6-14 50660002, 3-1-27 50840004, 3-1-14, 3-1-16, 3-1-17 50842004, 3-1-14, 3-1-15 5087000x, 4-2-20 50930001, 2-3-2 50960001, 2-3-2 5270 0001, 6-3-1, 6-3-3, 6-3-4 52790001, 2-1-3 5280000x, 3-5-2 52820001, 3-7-7, 3-7-10 5285000x, 3-1-13 52960001, 4-1-1 53190004, 6-4-48 5319000x, 6-4-29 5320000x, 5-4-2 5324000x, 3-1-8 5349000x, 6-4-29 5352 0006, 6-3-1, 6-3-46 53520006, 6-6-7 5355 0006, 6-3-1, 6-3-46 53910001, 7-6-7 54040004, 6-4-44, 6-6-10 5408 0004, 6-4-46 54080004, 6-6-10 5409000x, 1-2-32 54340xxx, 7-2-3 54440002, 5-1-24, 5-1-35 54470002, 5-1-41 54500005, 5-1-35 54530001, 5-1-4 54560001, 5-1-4 5477000x, 6-4-4 RS3: Service Manual 54850001, 5-4-20 5488 0001, 5-4-13 5503000x, 1-2-28 55270010, 3-7-27 55270011, 3-7-27 5590 xxxx, 5-1-4 56120001, 3-1-26 56450002, 1-2-28 5645000x, 1-2-18 5658000x, 1-2-2 5662000x, 1-1-1 5664000x, 1-2-13 5665000x, 3-5-2 56700015, 3-4-7 5685000x, 3-5-23 57070001, 6-4-39 57240002, 5-1-35 57520007, 4-3-2 57560001, 1-2-32 57700005, 6-4-44, 6-6-10 58050001, 3-5-2 58570001, 3-5-2 1166-0505--0021, 3-6-23 0524--0010, 3-1-31 0524--00xx, 3-2-10 1167-0016--0002, 2-1-12 0016--0006, 9-3-3 0016--0007, 2-1-12 0016--000x, 2-1-12 1216/CW--ROS4, 6-6-3 12P, 0373x032, 3-1-26, 3-4-3 1301/PZ, 6-6-3 16--Point Input FIMs, 6-4-44 16--Point Output FIMs, 6-4-46 1822 C0 0030 CC, 6-6-8 1842 C0 0030 CC, 6-6-8 1862 L0 0060 CC, 6-6-8 1872 L0 0060 WW, 6-6-8 1882 L0 0060 UU, 6-6-8 1882 L0 0060 WW, 6-6-8 1984-0023--000x, 4-1-1 0158--00xx, 1-4-9 0158--10xx, 1-4-9 0158--20xx, 1-4-7 Index SV: Index-2 0283--000x, 1-4-3 0298--000x, 1-2-2 0303--000x, 1-1-1 0317--000x, 3-6-20 0359--000X, 9-1-3 0360--000x, 5-2-22 0361--00xx, 5-2-22 0373--00xx, 1-4-3 0373--xxxx, 1-3-9 0390--000x, 1-2-13 0393--000x, 1-2-23 0484--0002, 2-1-3, 2-3-2 0488--000x, 2-1-3 0489--000x, 2-1-3 0498--0005, 6-3-28 0510--000x, 3-6-16 0514--000x, 2-2-8 0533--000x, 3-6-9 0543--000x, 3-6-6 0605--000x, 5-3-4 0607-0003, 5-3-16 0009, 5-3-16 000x, 5-3-14, 8-4-9 0620--000x, 5-3-2 0628--000x, 5-3-5 0657--000x, 3-2-5 0660--000x, 3-7-7, 3-7-14 0672--000x, 3-3-11 0744--000x, 3-7-5 1002--000x, 3-3-7 1011--000x, 3-7-46 1017--000x, 3-7-20 1045--000x, 3-7-15 1046--000x, 1-2-20 1050--000x, 3-3-14 1053--000x, 3-3-12 1064--000x, 3-7-42 1089--000x, 1-2-26 1129--000x, 5-5-34 1137--000x, 3-7-20 1140--000x, 3-7-52 1144--000x, 1-4-3 1147--000x, 3-7-60, 3-7-62 1161--000x, 3-7-30 1167--000x, 3-7-60, 3-7-62 1175--000x, 5-2-2, 5-2-7 1176--000x, 5-5-2 1189--0001, 2-2-13 1191--0001, 2-2-3 1192--0001, 2-2-3 1193--0002, 2-2-6 1194--0002, 2-2-6 1195--000x, 2-2-7 1195--xxxx, 2-2-5 1196--000x, 2-2-7 1196--xxxx, 2-2-5 1198--000x, 2-2-9 1224--000x, 4-2-39 1231--0001, 4-1-7 1240--000x, 4-2-20 RS3: Service Manual 1243--0001, 1249--000x, 1273--000x, 1274--000x, 1283--000x, 1288--000x, 1300--000x, 1304--000x, 1321--000x, 1325--000x, 1334--000x, 1336--000x, 1356--000x, 1362--000x, 1364--000x, 1371--000x, 1374--000x, 1394--000x, 1402--000x, 1432--000x, 1439--000x, 1442--000x, 1445--000x, 1448--000x, 1460--000x, 1463--000x, 1469--000x, 1483--000x, 1490--000x, 1494--000x, 1502--000x, 1505--000x, 1525--000x, 1540--000x, 1543--000x, 1547--000x, 1587--000x, 1594--000x, 1598--000x, 1631--000x, 1632--000x, 1634--000x, 1651--0006, 1651--0013, 1651--0027, 1651--00xx, 1653--000x, 1654--000x, 1693--000x, 1694--000x, 1695--000x, 1731--000x, 1754--000x, 1776--000x, 1779--000x, 1782--000x, 1803--000x, 1825--000x, 1872--000x, 1915--000x, 1921--000x, 4-1-7 4-3-20 5-5-21 1-4-5 1-2-9 5-2-13 5-5-4 5-2-23 5-2-12 5-5-15 5-5-27 5-2-2 5-5-5 5-5-33 5-2-28 4-3-25 4-3-28 5-5-8 4-2-2 4-2-13 4-3-20 4-3-25 4-3-28 4-2-20 5-2-23 5-5-8 5-5-27 4-2-39 5-5-21 4-3-30 4-2-2 4-2-13 5-5-27 3-7-30 5-1-57 3-7-60, 3-7-69 8-3-1 4-2-20 4-2-39 3-1-8 3-1-9 3-1-6 3-1-30 3-1-30 3-1-30 3-1-31 3-1-8, 9-1-5 3-1-6 3-1-8 3-1-9 3-1-7 3-2-4 3-5-18 3-2-4 3-2-4 3-2-6 3-5-18 3-2-5 3-2-8 3-2-4 3-2-6 Index SV: Index-3 1927--000x, 1928--000x, 1934--000x, 1970--000x, 1975--000x, 1978--0004, 1978--000x, 1981--000x, 1989--000x, 2154--000x, 2171--000x, 2231--0001, 2307--000x, 2321--000x, 2347--00xx, 2350--000x, 2372--000x, 2386--000x, 2402--000x, 2409--000x, 2412--000x, 2415--0001, 2441--000x, 2448--000x, 2456--000x, 2457--000x, 2458--000x, 2459--000x, 2461--000x, 2462--0001, 2466--000x, 2483--000x, 2491--000x, 2494--0001, 2497--000x, 2500--000x, 2503--000x, 2504--9002, 2507--0002, 2507--000x, 2510--0001, 2510--000x, 2512--000x, 2518--000x, 2519--000x, 2526--000x, 2530--0001, 2533--0001, 2533--000x, 2535--9901, 2543--000x, 2546--000x, 2551--000x, 2552--000x, 2576--000x, 2597--000x, 2616--000x, 2618--000x, 2622--0001, 2624--0001, 2627--0001, 3-5-23 3-5-2, 3-5-15 3-2-4 3-1-12 3-1-13 3-1-19 3-1-14, 3-1-16 3-1-13 3-5-23 9-1-4, 9-3-2 7-3-3 2-2-3, 2-3-2 3-5-2, 3-5-13 3-1-10 4-2-39 2-2-8 3-1-6 3-1-6 5-4-13 5-4-2 5-5-13 5-1-54 5-4-20 5-1-54 5-3-10 5-3-7 5-3-9 5-2-16 5-1-53 7-4-5 5-3-10 5-1-35 5-1-4 5-1-13 5-1-2 4-3-2 3-7-39 7-4-3, 7-4-5 7-4-3 7-4-8 7-4-3, 7-4-5 7-4-8 5-1-54 5-1-24 5-1-35 5-1-2 7-4-1 7-4-3 7-4-4 7-4-3, 7-4-5 5-1-4 5-1-41 5-1-18 6-2-2, 6-2-9 5-2-2, 5-2-4 5-1-2 5-1-57 5-1-57 7-4-5, 7-4-6 7-4-6 7-4-1 RS3: Service Manual 2628--x006, 2633--000x, 2662--000x, 2731--000x, 2780--000x, 2783--9045, 2837--000x, 2844--000x, 2859--00xx, 2871--000x, 2889--0004, 2889--1004, 2891--000x, 3004--000x, 3005--9030, 3017--000x, 3023--000x, 3028--000x, 3038--000x, 3040--000x, 3062--00xx, 3065--00xx, 3067--xxxx, 3100--000x, 3202--0010, 3211--0001, 3211--0002, 3214--0002, 3222--0004, 3222--1004, 3222--2004, 3223--xxxx, 3245--0001, 3246--000x, 3261--0002, 3267--xxxx, 3270--0001, 3278--000x, 3286--000x, 3287--9500, 3289--000x, 3301--000x, 3318--000x, 3389--000x, 3442--0003, 3500--000x, 3505--000x, 4064--000x, 4068--000x, 4080--000x, 4121--000x, 4124--000x, 4127--000x, 4164--000x, 4167--000x, 4186--00xx, 4195--000x, 4195--00xx, 4196--0001, 4196--000x, 4205--000x, 7-4-3, 7-4-5 3-1-27 3-1-13 5-1-46, 8-2-1 3-5-2, 3-5-11 5-1-4 3-5-16 3-1-10 7-3-6 3-1-12 3-1-14, 3-1-16, 3-1-18, 3-1-21 3-1-14, 3-1-22 9-1-4 1-2-18 3-1-27 3-1-6 1-2-18 4-1-1 3-1-11 3-1-11 5-3-3 3-1-35 3-1-22 3-5-2, 3-5-10 3-7-27 2-2-3 2-2-6 2-2-6 3-1-14, 3-1-16, 3-1-17 3-1-14, 3-1-20 3-1-14, 3-1-15 3-1-17 3-1-27 3-1-27 7-4-3, 7-4-5, 7-4-8 3-1-20 4-1-5 6-2-11 3-1-27 3-1-27 3-5-23 3-7-52 3-6-2 3-5-23 1-2-14 3-5-2 4-2-7 4-2-20 4-3-2 6-3-1, 6-3-46, 6-6-7 6-3-1, 6-3-28 6-3-1, 6-3-28 6-3-1, 6-3-3, 6-3-14 4-2-20 6-3-1, 6-3-41 6-3-28 6-3-18, 6-3-33 6-4-25 6-3-18 6-3-33 6-2-2, 6-2-6 Index SV: Index-4 4282--000x, 6-3-1, 6-3-23 4302--000x, 1-2-28 4309--0004, 1-2-28 4329--000x, 1-2-28 4344--000x, 6-3-1, 6-5-2 4350--000x, 1-2-28 4383--000x, 6-4-17 4398--000x, 6-4-39 4409--000x, 6-2-2, 6-2-9 4414--000x, 6-4-44 4418--000x, 6-4-46 4433--000x, 1-2-28 4438--000x, 7-6-3 3.5--inch floppy disk drive, 3-5-16 32--Point Input FIM, 6-4-48 3M Static Pad, 9-3-2 4--20 mA ANALOG INPUT FIELD INTERFACE MODULE, 6-4-44, 6-4-46 4--20 MA FEM, calibrating, 8-4-7 4--20 MUX MARSHALLING PANEL, 5-3-9 5 1/4--inch floppy disk drive, 3-5-18 50P, 0589 0103, 6-2-6, 6-2-15 551 Barco CRT, 3-1-35 55P 0144x022, 3-1-26, 3-4-3 0416X012, 9-1-3 601077, 6-6-3 68020 OI Processor, 3-7-30 68040 OI Processor, 3-7-27 70983--, 0039, 9-3-2 7122 Conrac CRT, 3-1-30 7211 Conrac CRT, 3-2-8 7241 Conrac CRT, 3-1-30 7900-0317--0023, 3-2-8 408--0001, 7-5-6 A A Bus DC Power Distribution Cable, 1-4-9 AC Distribution Block, 1-2-28 fuse, 1-2-37 AC distribution switch assembly, 1-2-18 AC Entrance Panel, 1-1-1 dual feed, 1-1-4 single feed, 1-1-3 AC input, 1-1-1 AC/DC Power Supply, 1-3-1 (with battery backup), 1-2-2 fuses, 1-2-8 LEDs, 1-2-7 (without battery backup), 1-2-13 measuring output current, 1-2-15 battery and charger replacement, 9-2-2 checking battery, 9-1-27 installing, 1-3-1 with battery backup, alarm contacts, 1-2-6 without battery backup alarm contacts, 1-2-16 RS3: Service Manual LEDs, 1-2-16 AC/DC Power Supply to DC Bus Cable, 1-4-3 AC/DC Unregulated Power Supply, 1-2-26 fuses, 1-2-27 active hardware alarms, checking, 9-1-13 alarm contacts, AC/DC Power Supply with battery backup, 1-2-6 without battery backup, 1-2-16 Alarm Output Board, 3-7-5 Alarm Output Panel, 3-7-5 alphanumeric keyboard, 3-1-6 Pedestal Command Console, 3-2-5 Analog Card Cage, 5-1-2 address label, 5-1-3 FICs, 5-1-23 hardware, 5-1-1 Analog Extender Card, 5-1-53 Analog FIC, 5-1-24 fuses, 5-1-34 jumpers, 5-1-31 LEDs, 5-1-30 redundancy, 5-1-28 Analog FIC Extender Card, 5-5-33 Analog FIC W/Smart Transmitter Daughterboard, 5-1-35 fuses, 5-1-37 jumpers, 5-1-37 LEDs, 5-1-36 Analog I/O, troubleshooting procedures, 10-5-8 ANALOG I/O CAGE MOTHERBOARD, 5-1-2 Analog I/O FIC, calibrating, 8-5-1 Analog Input FIC, 5-5-7 ANALOG INPUT NON--ISOLATED, 5-5-8 ANALOG MARSHALING PANEL, 5-3-7 Analog Marshaling Panel, 5-1-54 ANALOG MARSHALLING PANEL, 5-1-54 Analog Output FIC, 5-5-20 ANALOG OUTPUT ISOLATED, 5-5-27 ANALOG TRANSFER, 5-1-13 Analog Transfer Card, 5-1-13 fuse, 5-1-17 LEDs and test points, 5-1-16 Analog FIM, redundancy, 6-4-43 automatic, memory dump, 10-3-12 Auxiliary Terminal Block, 5-1-57 B B Bus DC Power Distribution Cable, 1-4-9 Balance Mode, 5-1-19 Barco CD 551 Service Manual, 3-1-35 User Manual, 3-1-35 Basic Command Console, 3-2-1, 3-2-2 parts replacement, 9-2-5 BATTERY CHARGER AND DISPLAY DRIVER/ALARM, 1-2-9 Battery Charger Card, 1-2-9 fuse, 1-2-12 jumpers and test points, 1-2-11 Index SV: Index-5 Battery Replacement, battery charger card, 1-2-12 battery replacement AC/DC Power Supply, 9-2-2 OI NV RAM, 3-7-81 OI NV RAM Card, 9-2-4 RAM NV Memory, 4-2-49 Black Box Cable Assembly, 7-3-5 Data Converter, 7-3-5 BLOCK CONFIGURATOR SWITCH MATRIX, 3-2-4 broadcast messages, 10-2-14 bubble. See NV Memory Bubble Nonvolatile Memory. See NV Memory, bubble Bubble NV Memory. See NV Memory, bubble Bus A/B DC Power Distribution Cable, 1-4-7 Bypass Mode, 5-1-19 C C 12243, 5-2-20, 6-3-38 1285, 2-1-12 12918, 9-1-3 52932--0002, 4-2-49 C--1404S, 3-1-27 C52932, --0002, 3-7-81 C53394--, 0250--0005, 5-1-55 cabinet, electronics, 3-7-2 cabinet door filter, cleaning, 9-1-9 cabinet fan screen, cleaning, 9-1-9 cabinet filter, cleaning, 9-1-8 cabinet surface, cleaning, 9-1-11 cable A Bus DC Power Distribution, 1-4-9 AC/DC Power Supply to DC Bus, 1-4-3 B Bus DC Power Distribution, 1-4-9 Bus A/B DC Power Distribution, 1-4-7 DC Bus to DC Bus, 1-4-3 DC Bus to DC Bus Jumper, 1-3-9 fiber optic, 2-2-13 Keyboard Interface to Dual Keyswitch, 3-1-17 Keyboard Interface to Keyswitch, 3-1-21 Keyboard Interface to Remote Keylock, 3-1-20, 3-1-22 Opto/Electric, 2-2-7 QBUS Board 1 to Board 2, 7-4-3, 7-4-5 QBUS Boards to MP, 7-4-3, 7-4-5 twinax PeerWay, 2-1-9 calibrating 4--20 MA FEM, 8-4-7 Analog I/O FIC, 8-5-1 Input Points, 8-5-8 Isolated Output Points, 8-5-7 Non--Isolated Output Points, 8-5-6 Output Points, 8-5-3, 8-6-1, 8-6-4 Multiplexer FEMs, 8-4-2 MUX FEM, 8-4-1 Pulse Input FIC, 8-3-1 RS3: Service Manual Serial I/O FIC, 8-1-1 Analog Input Points, 8-1-5 Analog Output Points, 8-1-2 Temperature Input FIC, 8-2-1 Thermocouple FEM, 8-4-3 Voltage Input FEM, 8-4-3 calibration, checking, 9-1-18 CC, 4-3-28 LEDs, 4-3-33 fuse, 4-3-29 CF TERMINATOR II, 4-1-5 Character Graphics Video Generator, 3-7-42 fuse, 3-7-45 LEDs, 3-7-44 checking 4--20 MA FEM, 8-4-8 AC/DC Power Supply battery, 9-1-27 active hardware alarms, 9-1-13 Analog I/O FIC Input Points, 8-5-9 Output Points, 8-5-4 Console Power Regulator Card voltages, 9-1-24 I/O calibration, 9-1-18 LEDs, 9-1-12 RTD FEM calibration, 8-4-9 Serial I/O FIC Analog Input Points, 8-1-6 Analog Output Points, 8-1-3 System Power Supply voltages, 9-1-26 Temperature Input FIC, 8-2-6 Thermocouple FEM, 8-4-5 Thermocouple Sensor calibration, 8-2-6 Voltage Input FEM, 8-4-5 voltages, 9-1-19 cleaner kit, tape drive, 9-1-4 cleaning cabinet door filter, 9-1-9 cabinet fan screen, 9-1-9 cabinet filters and screens, 9-1-8 cabinet surfaces, 9-1-11 Command Console Fan filter, 9-1-6 Command Console glare filter, 9-1-14 console fan filter, 9-1-6 ControlFile Fan Filter, 9-1-9 floppy disk drives, 9-1-4 OI Card Cage filter, 9-1-10 tape drives, 9-1-4 trackball, 9-1-5 Cold Junction Compensator, 5-1-57 color codes, DC wiring, 1-4-10 COMM TERM PNL II, 6-2-2 COMM TERMINATION PNL, 6-2-2 Command Console cleaning CRT, 9-1-14 degaussing CRT, 9-1-15 fan filter, 9-1-6 hard disk drive removal, 9-2-6 keyboard, tape, or floppy disk removal, 9-2-9 parts replacement, 9-2-5 Command Entry Keyboard, Pedestal Command Console, 3-2-4 Index SV: Index-6 COMMAND ENTRY SWITCH MATRIX, 3-2-4 Communication Card, MUX, 5-3-5 communication wiring, Multipoint I/O, 6-1-10 Communications Connect Card, 5-1-4 Communications Connect Card II, 5-1-4, 5-1-10 jumpers, 5-1-10 Communications Connect Card III, 5-1-4 Communications Connect Card III / IV / V, 5-1-6 communication wiring, 5-1-7 jumpers, 5-1-8 Communications Connect Card IV, 5-1-4 Communications Connect Card V, 5-1-4 COMMUNICATIONS CONNECT III, 5-1-4 COMMUNICATIONS CONNECT IV, 5-1-4 COMMUNICATIONS CONNECT V, 5-1-4 Communications FlexTerm, 5-4-2 Communications Register Unit, 7-5-6 Communications Termination Panel, 6-2-2 Configuration Keyboard, 3-1-6 Pedestal Command Console, 3-2-4 Configure HIA Screen, 7-3-9 connector fiber optic PeerWay, 2-2-13 twinaxial PeerWay, 2-1-12 Connector Crimp Tool, 2-1-12 Conrac 7122, 3-1-30 Conrac 7211 maintenance manual, 3-2-8 spare parts, 3-2-10 Conrac 7241, 3-1-30 components, 3-1-31 Installation and Operation Manual, 3-1-30 User Guide, 3-1-30 Conrac 7241 CRT black video or black bars, 3-1-34 power--up diagnostics failures, 3-1-34 Scan Board adjustments, 3-1-33 Scan Board failures, 3-1-32 Console, CRT, 3-1-26 console Basic Command, 3-2-1 diagnostic programs, 9-1-16 Hardened Command, 3-1-1 Memory Dump screen, 10-3-12 Multitube, 3-1-1 Off--Line Diagnostic screen, 10-3-8 off--line diagnostics, 9-1-17, 10-3-8 Pedestal, 3-2-1 power--up diagnostics, 10-3-3 troubleshooting procedures, 10-3-1 Console Card Cage. See OI Card Cage console node address, 3-7-18 Console Off--Line Diagnostics screen, 10-3-8 Contact Card Cage, 5-2-1, 5-2-2, 5-2-4 FIC addressing, 5-2-5 fuse, 5-2-12 jumpers, 5-2-10 wiring, 5-2-6 Contact Card Cage Extender Card, 5-2-28 Contact Controller Processor. See CC Contact FIC, 5-2-23 RS3: Service Manual fuses, 5-2-27 jumpers, 5-2-26 LEDs, 5-2-25 Contact Field Interface Card, 5-2-23 CONTACT FIELD TERMINATION, 5-2-13 Contact FlexTerm, 5-2-2, 5-2-7 FIC addressing, 5-2-8 fuse, 5-2-12 jumpers, 5-2-10 Motherboard, 5-2-7 replacement, 9-2-13 wiring, 5-2-8 Contact FlexTerm Extender Card, 5-2-28 Contact FlexTerm II, 5-2-7 CONTACT FLEXTERM MOTHERBOARD, 5-2-7 CONTACT FLEXTERM MOTHERBOARD II, 5-2-7 Contact I/O, 5-2-23 CONTACT I/O PROCESSOR, 4-3-28 Contact Marshaling Panel, 5-2-16 fuse, 5-2-19 wiring, 5-2-17 CONTACT PROCESSOR, 4-3-28 Contact Termination Board, 5-2-13 fuse, 5-2-15 wiring, 5-2-14 Contact Termination Panel, 5-5-5 fuses, 5-5-6 ControlFile, 4-2-1 5 V DC Only Power Regulator, 4-2-7 fuse, 4-2-12 jumpers, 4-2-11 LEDs and test points, 4-2-9 Card Cage, 4-1-1 jumpers, 4-1-3 Motherboard, Data Bus Terminators, 4-1-5 Power Regulator 5 and 12 V DC, 4-2-13 fuses, 4-2-19 jumpers, 4-2-18 LEDs and test points, 4-2-16 Support Section, 4-2-1 troubleshooting, 10-4-1 ControlFile fan filter, cleaning, 9-1-9 CONTROLFILE POWER REGULATOR, 4-2-13 CONTROLFILE POWER REGULATOR 5V ONLY, 4-2-7 ControlFile Power Regulator Card adjustment, 9-1-21 checking voltages, 9-1-19 ControlFile Status screen, 10-4-7 ControlFile Terminator Board, 4-1-7 ControlFile Terminator II, 4-1-5 Controller Processor, 4-3-1 Contact, 4-3-28 Enable/Disable Switch, 4-3-36 jumpers, 4-3-37 LED sequence on power up, 4-3-32 LEDs, 4-3-32 Multi--Loop, 4-3-20 MultiPurpose, 4-3-2 Single--Strategy, 4-3-25 MPC, 4-3-2 Index SV: Index-7 Multiplexer, 4-3-30 Programmable Logic Controller, 4-3-30 redundancy, 4-3-39 COORDINATOR PROCESSOR, 4-2-20 Coordinator Processor. See CP COORDINATOR PROCESSOR EXTENDER, 5-2-28 COORDINATOR PROCESSOR II, 4-2-20 COORDINATOR PROCESSOR IV, 4-2-20 COORDINATOR PROCESSOR IV+, 4-2-20 Cover Plate, DEC, 7-4-5 CP, 4-2-20 enable/disable switch, 4-2-29 fuses, 4-2-38 jumpers, 4-2-34 LED sequences, 4-2-31 LEDs, 4-2-29 redundancy, 4-2-27 test points, 4-2-29 CPI, 4-2-20 II, 4-2-20 IV, 4-2-20 IV+, 4-2-20 CP-I, 4-2-20 circuit description, 4-2-24 CP-II, 4-2-20 circuit description, 4-2-24 CP-IV, 4-2-20 circuit description, 4-2-21 CP-IV+, 4-2-20 CPD-1304, 3-1-27 1304S, 3-1-27 1430, 3-1-27 CPU Card, QBI, 7-4-3, 7-4-5 Crimp Tool Kit, 2-1-12 CRT Barco 20”, 3-1-35 Conrac 19”, 3-1-30 Console, 3-1-26 Hitachi 21”, 3-1-26 Iiama Vision Master 17”, 3-1-26 Mag Innovision 15”, 3-1-27 maintaining, 9-1-14 problems, 10-3-22 Sony 14”, 3-1-27 ViewSonic 17”, 3-1-26 Current MUX Marshaling Panel, 5-3-9 D Data Bus Terminators, 4-1-5 DATAWAY TAP A, 2-1-3 DATAWAY TAP B, 2-1-3 daughterboard, 5-1-36 DC color codes, 1-4-10 distribution cabling, 1-4-7 RS3: Service Manual output card, 1-4-5 power distribution, 1-4-1 power distribution bus, 1-4-3 DC Bus to DC Bus Jumper Cable, 1-4-3 DC Distribution Block, 1-2-28 fuse, 1-2-37 DC OUTPUT, 1-4-5 DC Output Card, 1-4-5 fuses, 1-4-6 DC Power Distribution Bus, 1-4-3 DC/DC Power Supply, 1-2-23 fuses, 1-2-25 degaussing, Command Console CRT, 9-1-15 Degaussing Coil, 9-3-2 diagnosing Console PeerWay problem, 10-2-36 ControlFile PeerWay problem, 10-2-37 multiple ControlFiles, 10-2-39 one ControlFile, 10-2-37 SCI PeerWay problem, 10-2-36 diagnostic programs, console, 9-1-16 Diogenes Communication Converter Box, 7-5-7 Interface, 7-5-1 Interface Software, 7-5-5 TI Communications Card, 7-5-6 Direct Discrete Termination Panel, 6-3-1, 6-3-3, 6-3-14 field wiring, 6-3-16 fuses, 6-3-22 input points, 6-3-20 installation, 6-3-16 jumpers, 6-3-21 labels, 6-3-18 output points, 6-3-20 Direct Discrete Termination Panel II, 6-3-1, 6-3-3, 6-3-4 field wiring, 6-3-9 fuse, 6-3-13 installation, 6-3-8 jumpers, 6-3-10 DIRECT DISCRETE TERMINATION PNL, 6-3-14 DISCRETE FIELD INTERFACE MODULE, 6-3-46 Discrete Field Interface Module (FIM), 6-3-1, 6-3-46 DISCRETE FIELD INTERFACE MODULE: HIGH SIDE SWITCH, 6-3-46 DISCRETE FIELD INTERFACE MODULE: LOW SIDE SWITCH, 6-3-46 Discrete FIM LED patterns, 6-3-51 LEDs, 6-3-50 online replacement, 6-3-48 precision, 6-3-49 redundancy, 6-3-48 Discrete I/O, 6-3-1, 6-3-2 Discrete Switch Panel, 5-2-22 Discrete Termination Panel Direct, 6-3-14 Direct II, 6-3-4 High Density Isolated, 6-3-41 Index SV: Index-8 Isolated, 6-3-28 Multi--FIM, 6-3-23 disk--only SCSI, 3-7-52, 3-7-57 distribution block AC, 1-2-28 DC, 1-2-28 Distribution Blocks, 1-2-37 Dual Feed AC Entrance Panel, 1-1-4 fuses, 1-1-5 dump memory, 10-3-12 automatic, 10-3-12 viewing, 10-3-16 DVM, 9-3-2 E EIA Options, SCI, 7-2-15 EIGHT LINE COMM CONNECT, 5-1-4 Elcon Intrinsically Safe Termination Panel, 6-6-3 Analog Applications, 6-6-9 Discrete Applications, 6-6-6 electrical PeerWay, 2-1-1 grounding, 2-1-7 termination, 2-1-11 Electrical Tap Box, 2-2-6 Electronics Cabinet, 3-7-2 Engineering Keyboard, 3-1-6 Enhanced Engineering Keyboard, 3-1-6 Ethernet cable, 3-4-8 hubs, 3-4-11 Extender Card Analog, 5-1-53 Analog FIC, 5-5-33 Contact Card Cage, 5-2-28 Contact FlexTerm, 5-2-28 MPC, 5-1-53 SIO, 5-1-53 F FEM, 5-3-14 Thermocouple, 5-3-16 Universal Voltage, 5-3-16 Voltage, 5-3-16 fiber optic cable and accessories, 2-2-13 Cable Tie Panel Assembly, 2-2-3 connector kit, 2-2-13 I/O Converter, 6-2-11 installing connectors, 2-2-13 Fiber Optic Cable Tie Panel Assembly, 2-2-3 Fiber Optic I/O Converter, 6-2-11 fiber optic PeerWay, troubleshooting cables, 10-2-42 Fiber Optic Power Meter, 9-3-3 RS3: Service Manual FIBER OPTIC REPEATER, 2-2-8 Fiber Optic Source meter, 9-3-3 FIC, 5-1-23, 5-5-1 4--20 MA, 5-1-24 4--20 mA W/Smart Daughterboard, 5-1-35 Analog, 5-1-24 Analog Input, 5-5-7 Analog Output, 5-5-20 Detail screen, 10-5-18 Field I/O Status screen, 10-5-13 Isolated Analog Input, 5-5-15 Isolated Analog Output, 5-5-27 Non--Isolated Analog Input, 5-5-8 Non--Isolated Analog Output, 5-5-21 Pulse I/O, 5-1-41 restoring redundant, 10-5-2 RTD/TC, 5-1-46 Smart Transmitter, 5-5-13 Status screen, 10-5-13 TC/RTD, 5-1-46 Temperature Input, 5-1-46 FIC 2--IN 1--OUT/COMM EXTENDER BD, 5-1-53 FIC 4--20 MA, 5-1-24 FIC Detail screen, 10-5-18 field definitions, 10-5-18 FIC NON--ISOLATED INPUT, 5-5-8 Field I/O Status screen, 10-5-13 Field Interface Card. See FIC Field Interface cards, 5-1-23 field wiring Direct Discrete Termination Panel, 6-3-16 High Density Isolated Discrete Termination Panel, 6-3-43 Isolated Discrete Termination Panel, 6-3-31 Remote Communications Termination Panel I, 6-2-9 Remote Communications Termination Panel II, 6-2-6 filter console fan, 9-1-6 replacement, 9-1-3 FIM, Discrete, 6-3-46 FIM Detail screen, 10-5-18 FIM Status screen, 10-5-13 FlexTerm MUX, 5-3-2 replacement, 9-2-11 floppy disk drive, 3-5-16 3 1/2 inch, 3-5-16 5 1/4--inch, 3-5-18 cleaning, 9-1-4 Floppy Disk Power Supply, 3-3-14 fuses, 3-3-16 Floppy Drive Cleaner Kit, 9-1-4 FMS II Hubs, 3-4-12 Front End Modules (FEMs), 5-3-14 Fujitsu DL2600, 3-6-9 DL3800, 3-6-2 DL4600, 3-6-6 DPL24C, 3-6-16 Index SV: Index-9 fuse CC, 4-3-29 MLC, 4-3-24 MPCI, 4-3-19 PLC, 4-3-31 SSC, 4-3-27 AC Distribution Block, 1-2-37 AC input, 1-1-5 AC/DC Unregulated Power Supply, 1-2-27 Analog FIC, 5-1-34 Analog FIC W/Smart Transmitter Daughterboard, 5-1-37 Analog Transfer Card, 5-1-17 Battery Charger Card, 1-2-12 Character Graphics Video Generator, 3-7-45 Contact Card Cage, 5-2-12 Contact FIC, 5-2-27 Contact FlexTerm, 5-2-12 Contact Marshaling Panel, 5-2-19 Contact Termination Board, 5-2-15 Contact Termination Panel, 5-5-6 ControlFile 5 V DC Only Power Regulator, 4-2-12 Power Regulator 5 and 12 V DC, 4-2-19 CP, 4-2-38 DC Distribution Block, 1-2-37 DC Output Card, 1-4-6 DC/DC Power Supply, 1-2-25 Direct Discrete Termination Panel, 6-3-22 Direct Discrete Termination Panel II, 6-3-13 Floppy Disk Power Supply, 3-3-16 Isolated Analog Input FIC, 5-5-18 Isolated Analog Output FIC, 5-5-32 Isolated Discrete Termination Panel, 6-3-40 Keyboard Interface, 3-1-25 MARK 1 Remote Power Supply, 1-2-31, 1-2-34 Monochrome Video Generator, 3-3-10 MPC, 4-3-19 MPCII, 4-3-19 MTCC Remote Power Supply, 1-2-19 MUX, 4-3-31 Non--Isolated Analog Input FIC, 5-5-12 Non--Isolated Analog Output FIC, 5-5-26 NV Memory bubble, 4-2-53 RAM, 4-2-49 OI Power Supply, 3-7-24 OI Processor 68000, 3-7-38 OI Processor 68020, 3-7-33 OI Processor 68040, 3-7-29 OI Remote Power Supply, 1-2-20 Output Bypass Card, 5-1-22 PeerWay Buffer, 4-2-6 PeerWay Tap, 2-1-6 Pulse I/O FIC, 5-1-45 PX, 2-3-9 RS422/RS232 Port I/O Card, 5-4-19 RS422/RS422 Port I/O Card, 5-4-24 Smart Transmitter FIC, 5-5-14 Temperature Input FIC, 5-1-53 fuse label, Remote I/O Power Supply, 1-2-28 RS3: Service Manual fuses AC/DC Power Supply, (with battery backup), 1-2-8 used in RS3 (list), A-1 G G, 53373--0103, 6-2-6, 6-2-15 Grant Continuity Card, 7-4-8 grounding electrical PeerWay, 2-1-7 Optical PeerWay, 2-2-10 tape drive, 3-5-24 H hard disk, hardware, 3-5-2 Hardened Command Console, 3-1-1 HIA Configure HIA Screen, 7-3-9 direct connection of PeerWays, 7-3-3 hardware, 7-3-1 HIA/Black Box Cable Assembly, 7-3-5 Link Cable, 7-3-3 modem, 7-3-5 OI NV Memory jumpering, 7-3-7 Status screen, 7-3-11 HIA Bubble Memory, 3-7-60 HIA Link Cable, 7-3-3 HIA Modem, 7-3-5 HIA Status screen, 7-3-11 HIA/Black Box Cable Assembly, 7-3-6 HIGH DENSITY ISOLATED DISCRETE TERMINATION PANEL, 6-3-41 High Density Isolated Discrete Termination Panel, 6-3-1, 6-3-41 field wiring, 6-3-43 jumpers, 6-3-44 label, 6-3-43 solid state relays, 6-3-45 Highway Interface Adapter. See HIA host, 10-2-14 hubs, 3-4-11 Hybrid PeerWay, 2-3-1, 2-3-2 I IAC5, 5-2-20, 6-3-38 IAC5A, 5-2-20, 6-3-38 IBM Deskstar, 3-5-2 IC454--187, 7-3-5 IDC5, 5-2-20, 6-3-38 IDC5-B, 6-3-38 F, 6-3-38 IDC5B, 5-2-20 Index SV: Index-10 Controller Processor, 4-3-37 CP, 4-2-34 Direct Discrete Termination Panel, 6-3-21 Direct Discrete Termination Panel II, 6-3-10 floppy disk drive 3.5--inch, 3-5-16 High Density Isolated Discrete Termination Panel, 6-3-44 Isolated Analog Input FIC, 5-5-17 Isolated Analog Output FIC, 5-5-30 Isolated Discrete Termination Panel, 6-3-39 Keyboard Electronics Board, 3-1-12 Keyboard Interface, 3-1-24 MiniConsole 5 1/4 inch floppy disk drive, 3-5-20 MPCII, 4-3-12, 4-3-15 MTCC Remote Power Supply, 1-2-18 Multi--FIM Discrete Termination Panel, 6-3-26 Non--Isolated Analog Input FIC, 5-5-11 Non--Isolated Analog Output FIC, 5-5-25 NV Memory bubble, 4-2-53 RAM, 4-2-48 OI Bubble Memory, 3-7-67 OI NV RAM, 3-7-78 OI Power Supply, 3-7-23 OI Processor 68000, 3-7-37 OI Processor 68020, 3-7-33 OI Processor 68040, 3-7-29 Optical Repeater/Attenuator, 2-2-8 PeerWay Buffer, 4-2-5 PeerWay Interface, 3-7-18 PLC FlexTerm, 5-4-8 Printer Interface, 3-7-51 Pulse I/O FIC, 5-1-44 Remote Communications Termination Panel I, 6-2-10 Remote Communications Termination Panel II, 6-2-8 RS422/RS232 Port I/O Card, 5-4-17 RS422/RS422 Port I/O Card, 5-4-23 SCSI, 3-7-56 Smart Transmitter FIC, 5-5-14 tape drive, 3-5-25 Temperature Input FIC, 5-1-52 VAX QBUS Interface Board 1, 7-4-10 VAX QBUS Interface Board 2, 7-4-13 IDC5F, 5-2-20 IDC5G, 6-3-38 IDC5N, 6-3-38 installing AC/DC Power Supply, 1-3-1 Remote Communications Terminal Panel II, 6-2-6 Remote Communications Termination Panel I, 6-2-9 Smart Transmitter Daughterboard, 5-1-37 INTERFACE RS422--RS232, 5-4-13 INTERFACE RS422--RS422, 5-4-20 Intrinsic Safety, 6-6-1, 6-6-2 Elcon IS Termination Panel, 6-6-3 MTL IS Termination Panels, 6-6-14, 6-6-25 IS. See Intrinsic Safety Isolated Analog Input FIC, 5-5-15 fuses, 5-5-18 jumpers, 5-5-17 LEDs and test points, 5-5-16 Isolated Analog Output FIC, 5-5-27, 5-5-30 fuses, 5-5-32 LEDs and Test Points, 5-5-29 Isolated Discrete Termination Panel, 6-3-1, 6-3-28 field wiring, 6-3-31 fuses, 6-3-40 input points, 6-3-37 jumpers, 6-3-39 labels, 6-3-33 output points, 6-3-36 solid state relays, 6-3-38 ISOLATED DISCRETE TERMINATION PANEL A, 6-3-28 ISOLATED DISCRETE TERMINATION PANEL B, 6-3-28 ISOLATED INPUT, 5-5-15 ISOLATED OUTPUT FIC, 5-5-27 ISOLATED OUTPUT FIC 0--20 MA, 5-5-27 J Joystick, 3-1-11 Upgrade Kit, 3-1-11 JU475-2AEG, 3-5-18 3AEG, 3-5-18 4AEG, 3-5-18 jumpers Analog FIC, 5-1-31 Analog FIC W/Smart Transmitter Daughterboard, 5-1-37 Battery Charger Card, 1-2-11 Communications Connect Card III / IV / V, 5-1-8 Contact Card Cage, 5-2-10 Contact FIC, 5-2-26 Contact FlexTerm, 5-2-10 ControlFile, 4-1-3 5 V DC Only Power Regulator, 4-2-11 Power Regulator 5 and 12 V DC, 4-2-18 RS3: Service Manual K KEYBD INT./ VIDEO ISOLATOR, 3-1-15 KEYBD INTERFACE/VIDEO ISOLATOR, 3-1-15 keyboard, problems, 10-3-21 KEYBOARD ELECTRONICS, 3-1-12 Keyboard Electronics Board, 3-1-12 jumpers, 3-1-12 Touchpad, 3-1-13 trackball, 3-1-13 Keyboard Interface access, 3-1-23 fuses, 3-1-25 jumper, 3-1-24 Index SV: Index-11 LEDs, 3-1-24 Multitube Command Console, 3-1-14 Pedestal Command Console, 3-2-6 Keycap Puller, 3-1-6 Keyswitch Assembly, Pedestal Command Console, 3-2-5 L LEDs Controller Processor, 4-3-32 MPC, 4-3-33 MUX, 4-3-33 PLC, 4-3-33 AC/DC Power Supply (with battery backup), 1-2-7 without battery backup, 1-2-16 Analog FIC, 5-1-30 Analog FIC W/Smart Transmitter Daughterboard, 5-1-36 Analog Transfer Card, 5-1-16 CC, 4-3-33 Character Graphics Video Generator, 3-7-44 checking, 9-1-12 Contact FIC, 5-2-25 ControlFile 5 and 12 V DC Power Regulator, 4-2-16 ControlFile 5V DC Power Regulator, 4-2-9 CP, 4-2-29 DC Output Card, 1-4-5 Discrete FIM, 6-3-50 Fiber Optic I/O Converter, 6-2-16 Isolated Analog Input FIC, 5-5-16 Isolated Analog Output FIC, 5-5-29 Keyboard Interface, 3-1-24 LPM, 6-4-41 MAIO FIM, 6-4-49 Mark 1 Remote Power Supply, 1-2-31, 1-2-34 MiniConsole Floppy Interface, 3-3-13 MLC, 4-3-35 Monochrome Video Generator, 3-3-9 MUX Power Regulator, 5-3-5 Non--Isolated Analog Input FIC, 5-5-10 Non--Isolated Analog Output FIC, 5-5-24 NV Memory bubble, 4-2-52 RAM, 4-2-44 OI Bubble Memory, 3-7-65 OI NV RAM, 3-7-74 OI Power supply, 3-7-22 OI Processor 68000, 3-7-36 OI Processor 68020, 3-7-32 OI Processor 68040, 3-7-29 Optical Repeater/Attenuator, 2-2-8 Output Bypass Card, 5-1-21 PeerWay Buffer, 4-2-4 Pixel Graphics Video Generator, 3-7-41 Printer Interface, 3-7-49 Pulse I/O FIC, 5-1-43 RS3: Service Manual PX, 2-3-7 RS422/RS232 Port I/O Card, 5-4-16 RS422/RS422 Port I/O Card, 5-4-22 SCSI, 3-7-55 Smart Transmitter Daughterboard, 5-1-40 Smart Transmitter FIC, 5-5-13 SSC, 4-3-35 Temperature Input FIC, 5-1-51 VAX QBUS Interface Board 2, 7-4-15 VAX QBUS Interface Marshaling Panel, 7-4-7 LFD. See Line Fault Detection Line Fault Detection, 6-6-20 Local Field Termination Board, 5-2-13 LOOP CALLUP (32 SWITCHES), 3-2-4 Loop Callup Keyboard, Pedestal Command Console, 3-2-4 Loop Power Module. See LPM LPM, 6-4-39 fuses, 6-4-41 LEDs, 6-4-41 LPS 105S, 3-5-2 LPS 170S, 3-5-2 LPS 270S, 3-5-2 M M9047, 7-4-8 Mag Innovision CRT, 3-1-27 magnetic tape drive, 3-5-23 cleaner kit, 9-1-4 MAI32 Termination Panel, 6-4-29 Main Keyboard, 3-1-7 jumpers, 3-1-7 Replacement Subassembly, 3-1-7 Main Keyboard/Trackball, 3-1-6 Main Keyboard/Trackball/Option, 3-1-6 maintaining, CRT, 9-1-14 maintenance, scheduled, 9-1-1 MAIO, 6-4-1 FIM LEDs, 6-4-49 FIMs, 6-4-42 termination panels, 6-4-2 MAIO TERMINATION PANEL, 6-4-17 MAIO Termination Panel, 6-4-17 MAIO16 TERMINATION PANEL, 6-4-4 MAIO16 Termination Panel, 6-4-4 MARK 1 Remote Power Supply, fuses, 1-2-31, 1-2-34 Marshaling Panel Analog, 5-1-54 Contact, 5-2-16 Current MUX, 5-3-9 MicroVAX/PeerWay Interface, 7-4-4 MPC, 5-1-54 RTD MUX, 5-3-10 Serial, 5-1-54 VAX 3xxx/VAX4xxx PeerWay, 7-4-6 Voltage MUX, 5-3-7 Marshaling Panel Auxiliary Terminal Block, 5-1-57 MC PEERWAY, 3-7-15 Index SV: Index-12 MC VIDEO GENERATOR, 3-3-7 MDIO, 6-3-1, 6-3-46 MDIO MTL IS Termination Panel, 6-6-14 MDIO--MTL I.S. ISOLATOR BARRIERS TERMINATION PANEL A, 6-6-14 MDIO--MTL I.S.. ISOLATOR BARRIERS TERMINATION PANEL B, 6-6-14 MDIOH, 6-3-1, 6-3-46 MDIOL, 6-3-1, 6-3-46 memory, dump, 10-3-12 automatic, 10-3-12 Memory Dump screen, 10-3-12 Memory View screen, 10-3-16 field definitions, 10-3-16 Menu Confidence screen, 10-3-20 messages broadcast, 10-2-14 point--to--point, 10-2-14 MicroVAX II, QBI Hardware Kit, 7-4-3 MicroVAX II -- PeerWay Marshaling Panel, 7-4-3 MicroVAX/PeerWay Interface Marshaling Panel, 7-4-4, 7-4-6 mini--floppy interface card, 3-5-18 MINICON POWER REGULATOR, 3-7-20 MiniConsole, 3-3-1 CRT, 3-3-11 Floppy Disk Drive, 3-3-11 floppy disk drive, jumpers, 3-5-20 Floppy Interface (SCSI), 3-3-12 keyboards, 3-3-4 OI Processor Card, 3-3-6 PeerWay Interface Card, 3-3-6 Power Regulator Card, 3-3-6 Printer Interface, 3-3-11 Remote Power Supply, 3-3-16 MINICONSOLE PRINTER INTERFACE, 3-7-46 MLC, 4-3-20 function, 4-3-21 LEDs, 4-3-32 fuses, 4-3-24 LEDs, 4-3-35 MODE Pushbutton, 5-1-19 Monochrome Video Generator, 3-3-7 fuse, 3-3-10 LEDs, 3-3-9 Raster Test Button, 3-3-9 MPC, 4-3-2 fuses, 4-3-19 LEDs, 4-3-33 MPC Analog Card Cage, 5-1-2 MPC Analog FIC, 5-1-24 MPC Contact Card Cage, 5-2-2 MPC Contact FlexTerm, 5-2-2 MPC CONTACT FLEXTERM MOTHERBOARD, 5-2-4 MPC Marshaling Panel, 5-1-54 MPC5, 4-3-2 MPCI, 4-3-2 function, 4-3-10 MPCII, 4-3-2 function, 4-3-5, 4-3-7 RS3: Service Manual jumpers, 4-3-12, 4-3-15 MTCC Remote Power Supply, 1-2-18 fuse, 1-2-19 jumper, 1-2-18 MTL 4014, 6-6-22 4021, 6-6-22 4023, 6-6-22 4025, 6-6-22 4041B, 6-6-29 4041P, 6-6-29 4045B, 6-6-29 4046P, 6-6-29 MTL IS Termination Panels, 6-6-14, 6-6-25 MULTI LOOP PROCESSOR, 4-3-20 MULTI STRATEGY PROCESSOR, 4-3-20 Multi--FIM Discrete Termination Panel, 6-3-1, 6-3-23 jumpers, 6-3-26 label, 6-3-25 MULTI--FIM TERMINATION PANEL, 6-3-23 Multi--Loop Controller Processor. See MLC Multi--Loop FlexTerm, 5-5-1 replacement, 9-2-11 MULTI--PURPOSE CONTROLLER II, 4-3-2 MULTI--STRATEGY MARSHALLING PANEL, 5-1-54, 5-3-10 MultiLoop FlexTerm, 5-5-2 Multiplexer Controller Processor. See MUX Multiplexer FEM, calibrating, 8-4-2 Multiplexer FlexTerm Hardware, 5-3-1 MULTIPLEXER PROCESSOR, 4-3-30 Multipoint Analog I/O. See MAIO Multipoint Discrete I/O. See MDIO Multipoint I/O address jumpers, 6-1-4 addressing, 6-1-4 communication wiring, 6-1-10 grounding, 6-1-8 installation, 6-1-1, 6-1-8 online replacement, 6-1-6 power wiring, 6-1-8 redundancy, 6-1-6 scanning rate, 6-1-5 system cabling, 6-1-1 MultiPurpose Controller Processor. See MPC MultiPurpose Controller Processor II, 4-3-2 Multitube Command Console, 3-1-1 CRT Barco CD 551 and ICD 551, 3-1-35 Hitachi 21”, 3-1-26 Iiyama 17”, 3-1-26 Mag Innovision, 3-1-27 Sony, 3-1-27 ViewSonic 17”, 3-1-26 keyboard assembly, 3-1-4 keyboard electronics, 3-1-12 keyboard error reporting, 3-1-5 Keyboard Interface, 3-1-14 Multitube Electronics Cabinet, 3-7-2 MUX, 4-3-30 Index SV: Index-13 Communication Card, 5-3-5 fuse, 4-3-31 LEDs, 4-3-33 Power Regulator, 5-3-4 MUX Cable Assembly, 200 Points, 5-3-3 MUX FEM, calibrating, 8-4-1 MUX FlexTerm, 5-3-2 MUX Front End Modules (FEMs), 5-3-14 MUX MARSH PANEL, 5-3-9 MUX Marshaling Panels, 5-3-7 MUX Power Regulator, 5-3-4 LEDs, 5-3-5 N node address, 3-7-18 Node Dump screen, 10-3-19 NON--ISO & ISO ANALOG OUTPUT/INPUT CARD EXTENDER, 5-5-33 NON--ISO ANALOG OUTPUT, 5-5-21 Non--Isolated Analog Input FIC, 5-5-8 fuses, 5-5-12 jumpers, 5-5-11 LEDs and test points, 5-5-10 Non--Isolated Analog Output FIC, 5-5-21 fuses, 5-5-26 jumpers, 5-5-25 LEDs and test points, 5-5-24 NON--ISOLATED OUTPUT, 5-5-21 Nonvolatile Memory. See NV Memory NV BUBBLE MEMORY, 4-2-39 NV MEMORY, 4-2-39 NV Memory, 4-2-39 bubble, 3-7-62, 4-2-50 fuses, 4-2-53 jumpers, 4-2-53 LEDs, 4-2-52 problems, 10-6-1 test points, 4-2-52 RAM, 3-7-69, 4-2-41 battery replacement, 4-2-49 fuse, 4-2-49 jumpers, 4-2-48 LED sequences, 4-2-46 LEDs, 4-2-44 test points, 4-2-44 NV RAM, OI, 3-7-69 O OAC5, 5-2-20, 6-3-38 OAC5-1, 5-2-20, 6-3-38 A, 5-2-20, 6-3-38 OAC5A5, 5-2-20, 6-3-38 OBC, 5-1-18 OBU, 5-5-34 RS3: Service Manual ODC5, 5-2-20, 6-3-38 ODC5A, 5-2-20, 6-3-38 ODC5RM , 6-3-38 OI BUBBLE MEMORY, 3-7-60, 3-7-62 OI Bubble Memory, 3-7-62 jumpers, 3-7-67 LED Sequences, 3-7-66 LEDs, 3-7-65 OI BUBBLE MEMORY SC, 3-7-60, 3-7-62 OI Card Cage, 3-7-1, 3-7-7, 3-7-14 cleaning filter, 9-1-10 EMC Compliant, 3-7-7, 3-7-10 troubleshooting, 10-3-24 OI COLOR VIDEO, 3-7-42 OI GRAPHICS VIDEO GEN, 3-7-39 OI KEYBOARD INTERFACE, 3-2-6 OI MINI FLOPPY DISK CONTROLLER, 3-3-12 OI Nonvolatile Memory, 3-7-60 OI NV RAM, 3-7-60, 3-7-69, 3-7-74 battery replacement, 3-7-81, 9-2-4 jumpers, 3-7-78 LED Sequences, 3-7-77 OI POWER SUPPLY, 3-7-20 OI Power Supply, 3-7-20 fuses, 3-7-24 jumpers, 3-7-23 LEDs and test points, 3-7-22 OI Processor, 3-7-25 OI Processor 68000, 3-7-34 fuses, 3-7-38 jumpers, 3-7-37 LEDs, 3-7-36 OI PROCESSOR 68020, 3-7-30 OI Processor 68020, 3-7-30 fuses, 3-7-33 jumpers, 3-7-33 LEDs, 3-7-32 OI PROCESSOR 68020 W/ASIC, 3-7-30 OI Processor 68040, 3-7-27 fuses, 3-7-29 jumpers, 3-7-29 LEDs, 3-7-29 OI PROCESSOR V, 3-7-27 OI Remote Power Supply, 1-2-20 fuse, 1-2-22 OI SCSI HOST ADAPTER, 3-7-52 online replacement Discrete FIM, 6-3-48 Multipoint I/O, 6-1-6 Operator Interface Card Cage. See OI Card Cage operator keyboard, 3-1-6 jumpers, 3-1-7 Optical Isolator Module Contact I/O, 5-2-20 Discrete I/O, 6-3-38 High Density Isolated Discrete Termination Panel, 6-3-45 Optical PeerWay, 2-2-1, 2-2-2 grounding, 2-2-10 Optical Repeater/Attenuator, 2-2-8 jumpers and LEDs, 2-2-8 Index SV: Index-14 Optical Tap Box, 2-2-3 connecting cables, 2-2-5 Option Keyboard, 3-1-9 jumpers, 3-1-9 Replacement Subassembly, 3-1-9 OPTO Isolator, 5-2-20 Opto/Electric cable, 2-2-5– 2-2-7 ORR5--1, 6-3-38 OS KEYBOARD INTERFACE, 3-2-6 Output Bypass Card, 5-1-18, 5-1-19 fuses, 5-1-22 LEDs, 5-1-21 operating instructions, 5-1-21 Output Bypass Unit, 5-5-34 P Pansonic JU474--2AEG, 3-5-18 JU475--3AEG, 3-5-18 JU475--4AEG, 3-5-18 parts replacement, 9-2-1 Password Keyboard Interface , 3-1-15 PC compatible keyboard, 3-1-6 Pedestal Command Console, 3-2-1 Alphanumeric Keyboard (Rotating), 3-2-5 Command Entry Keyboard, 3-2-4 Configuration Keyboard, 3-2-4 CRT, 3-2-8 Disk Interface Card (SCSI), 3-2-11 Keyboard Interface, 3-2-6 keyboards, 3-2-3 Keyswitch Assembly, 3-2-5 Loop Callup Keyboard, 3-2-4 Power Supply, 3-2-11 Printer Interface Card, 3-2-11 Trackball Keyboard, 3-2-4 PeerWay Backup Node screen, 10-2-12 cable fault diagnostics, 10-2-40 electrical, 2-1-1 fault conditions, 10-2-30 fault detection, 10-2-31 fault diagnostics, 10-2-35 hybrid, 2-3-1, 2-3-2 Node screen, 10-2-12 optical, 2-2-1 Overview screen, 10-2-9 Performance screen, 10-2-3 sample problems, 10-2-29 screens, 10-2-1 twinax, 2-1-1 PeerWay Backup Node screen, 10-2-12 field definitions, 10-2-12 PeerWay Buffer, 4-2-2 fuse, 4-2-6 jumpers, 4-2-5 LEDs and test points, 4-2-4 PeerWay Drop Cables, MicroVAX, 7-4-3, 7-4-5 RS3: Service Manual PeerWay Extender. See PX PeerWay Field Termination Kit, 9-3-3 PeerWay Interface, 3-7-15 jumpers, 3-7-18 LEDs and test points, 3-7-17 PeerWay Interface Card, QBI, 7-4-3, 7-4-5 PeerWay Interface Devices, troubleshooting, 10-6-1 PeerWay Node screen, 10-2-12 field definitions, 10-2-12 PeerWay Overview screen, 10-2-9 field definitions, 10-2-9 use in fault detection, 10-2-33 PeerWay Performance screen, 10-2-3 field definitions, 10-2-3 PeerWay Tap fuses, 2-1-6 test points, 2-1-6 Peripheral Devices, disk drives, 3-5-1 Pixel Graphics Video Generator, 3-7-39 LEDs, 3-7-41 Plant Status screen, 10-2-2 PLC, 4-3-30, 5-4-1 Fuse, 4-3-31 FlexTerm, 5-4-2 hardware, 5-4-1 Port I/O Card Redundancy, 5-4-11 redundancy, 5-4-9 PLC FlexTerm, 5-4-2 jumpers, 5-4-8 point--to--point messages, 10-2-14 Port I/O Card, 5-4-13 redundancy, 5-4-11 RS422/RS232, 5-4-13 RS422/RS422, 5-4-20 power, redundancy, 1-5-1 power regulator MUX, 5-3-4 OI, 3-7-20 Power Regulator Card 5 and 12 Volt DC, 4-2-13 5V DC Only, 4-2-7 checking voltages, 9-1-24 ControlFile, checking voltages, 9-1-19 Inserting, 4-2-7, 4-2-13 power supplies, 1-2-1 POWER SUPPLY DISPLAY III, 1-2-14 power wiring, Multipoint I/O, 6-1-8 printer, 3-6-1 DL2600 (Fujitsu), 3-6-9 DL3800 (Fujitsu), 3-6-2 DL4600 (Fujitsu), 3-6-6 DPL24C (Fujitsu), 3-6-16 TI 810, 3-6-20 printer interface, 3-7-46 jumpers, 3-7-51 LEDs, 3-7-49 ProDrive. See Quantum Programmable Logic Controller. See PLC PULSE I/O, 5-1-41 Pulse I/O FIC fuses, 5-1-45 Index SV: Index-15 jumpers, 5-1-44 LEDs, 5-1-43 Pulse Input FIC, calibrating, 8-3-1 PX, 2-3-2 Q QBI, 7-4-1, 7-4-2, 7-4-3 Hardware Kit, 7-4-1 QBUS Board 1, 7-4-3, 7-4-5, 7-4-8 QBUS Board 2, 7-4-3, 7-4-5, 7-4-8 QBUS TO PEERWAY INTERFACE I, 7-4-8 QBUS TO PEERWAY INTERFACE I+, 7-4-8 QBUS TO PEERWAY INTERFACE II, 7-4-8 Quantum 80S, 3-5-2, 3-5-11 LPS 105S, 3-5-10 Q250, 3-5-2 Q280, 3-5-2, 3-5-13 Q540, 3-5-15 Quantum QM32100, 3-5-2 Quantum Thunderbolt, 3-5-2 R RAM Nonvolatile Memory. See NV Memory, RAM RAM NV Memory. See NV Memory, RAM Raster Test Button, Monochrome Video Generator, 3-3-9 RBLC FlexTerm, 5-4-2 reactivity coupon, use, 1-3-5, 1-3-16, 1-3-18, 1-3-19, 1-3-20, 1-3-21 Recommended Resistance, 6-3-4 redundancy Analog FIC, 5-1-28 Analog FIM, 6-4-43 Controller Processor, 4-3-39 CP, 4-2-27 Discrete FIM, 6-3-48 Multipoint I/O, 6-1-6 PLC, 5-4-9 PLC Port I/O Card, 5-4-11 power, 1-5-1 Thermocouple Sensor, 8-2-7 Remote Communications Termination Panel, 6-2-2 Remote Communications Termination Panel I, 6-2-2, 6-2-9 installing, 6-2-9 jumpers, 6-2-10 Remote Communications Termination Panel II, 6-2-2– 6-2-4 field wiring, 6-2-6 installing, 6-2-6 jumpers, 6-2-8 Remote I/O Power Supply, 1-2-28 Remote Keyswitch, 3-1-20 Remote Power Supply, 1-2-32 RS3: Service Manual remote power supply I/O, 1-2-28 MTCC, 1-2-18 OI, 1-2-20 remote termination panel, standard, 6-5-2 Repeater/Attenuator, optical, 2-2-8 Resistance Temperature Detector, 5-3-16 restore operations, redundant FICs, 10-5-2 RNI, 3-4-9, 7-6-1, 7-6-2 Fan Assembly, 7-6-7 PeerWay Node Label, 7-6-3 ROS CRT Hitachi 21”, 3-4-3 Iiama Vision Master 17”, 3-4-3 ROS Hardware, 3-4-1 Rotating (Alphanumeric) Keyboard, Pedestal Command Console, 3-2-5 router, 3-4-15 RPQNA, 7-4-5 RS--232C pin assignments, 7-2-4 SCI cabling, 7-2-3 signal names, 7-2-3 RS--422 pin assignments, 7-2-7 SCI cabling, 7-2-6 X.25 cabling, 7-2-11 X.25 clocking, 7-2-13 X.25 protocol, 7-2-9 signal names, 7-2-6 RS3 Network Interface (RNI), 3-4-9 Operator Station, 3-4-2 RS3 Network Interface, 7-6-1, 7-6-2 RS422/RS232 Port I/O Card, 5-4-13 fuse, 5-4-19 jumpers, 5-4-17 LEDs, 5-4-16 RS232 pin assignments, 5-4-15 RS422/RS422 Port I/O Card fuse, 5-4-24 jumpers, 5-4-23 LEDs, 5-4-22 RS422 pin assignments, 5-4-22 RTD, 5-3-16 RTD FEM, checking calibration, 8-4-9 RTD MUX MARSHALLING PANEL, 5-3-10 Rush Brush, 9-3-2 S scheduled maintenance, 9-1-1 SCI (Supervisory Computer Interface) EIA options, 7-2-15 hardware, 7-2-1 SCI Bubble Memory, 3-7-60 Scorpion 5945C, 3-5-23 5945S, 3-5-23 Index SV: Index-16 Scratchpad, 3-1-10 screen Configure HIA, 7-3-9 ControlFile Status, 10-4-7 FIC Detail, 10-5-18 FIC Status, 10-5-13 Field I/O Status, 10-5-13 FIM Detail, 10-5-18 FIM Status, 10-5-13 HIA Status, 7-3-11 Memory Dump, 10-3-12 Memory View, 10-3-16 Menu Confidence, 10-3-20 Node Dump, 10-3-19 Off--Line Diagnostics, 10-3-8 PeerWay Backup Node, 10-2-12 PeerWay Node, 10-2-12 PeerWay Overview, 10-2-9 PeerWay Performance, 10-2-3 Plant Status, 10-2-2 Screwdrivers, 9-3-1 SCSI, 3-7-52 jumpers, 3-7-56 LEDs, 3-7-55 SCSI BOARD 2, 3-7-52 Serial I/O, troubleshooting procedures, 10-5-3 Serial I/O FIC, calibrating, 8-1-1 SERIAL MARSHALLING PANEL, 5-1-54 SERIAL PROCESSOR, 4-3-2 Server, 10-2-14 Single Feed AC Entrance Panel, 1-1-3 SINGLE STRATEGY PROCESSOR, 4-3-25 Single--Strategy Controller Processor. See SSC Single--Strategy FlexTerm, 5-5-1, 5-5-4 analog wiring, 5-5-5 contact wiring, 5-5-5 replacement, 9-2-11 SIO, RTD/TC, 5-1-46 Small Computer System Interface. See SCSI Smart Transmitter Daughterboard Analog FIC, 5-1-35 installation, 5-1-38 Kit, 5-1-37 LEDs, 5-1-40 Smart Transmitter FIC, 5-5-13 fuses, 5-5-14 jumpers, 5-5-14 LEDs and test points, 5-5-13 SMART TRANSMITTER OPTION, 5-1-37 SMART XMTR FIC, 5-5-13 Socket, 10-2-14 solid state relay High Density Isolated Discrete Termination Panel, 6-3-45 Isolated Discrete Termination Panel, 6-3-38 Sony 14” CRT, 3-1-27 SRU, hardware, 7-1-1 SSC, 4-3-25 fuses, 4-3-27 LEDs, 4-3-35 Standard Keyswitch Keyboard Interface , 3-1-16 RS3: Service Manual STANDARD REMOTE TERMINATION PANEL, 6-5-2 Standard Remote Termination Panel, 6-3-1, 6-5-2 Star Coupler, 2-2-9 static pad, 9-3-2 status bits analog, 10-5-13 contact, 10-5-13 discrete I/O, 10-5-13, 10-5-18 pulse, 10-5-13 Supervisory Computer Interface. See SCI System Manager Station, 3-1-1 electronics cabinet, 3-7-4 System Power Supply, checking voltages, 9-1-26 System Resource Unit. See SRU T Tandberg, 5623, 3-5-23 tape drive, 3-5-1, 3-5-23 cleaning, 9-1-4 grounding, 3-5-24 jumpers, 3-5-25 switches, 3-5-25 Tape Drive Head Cleaner, Refill Kit, 9-1-4 Tape Drive Head Cleaning Kit, 9-3-2 TC/RTD FIC, 5-1-46 Temperature Input FIC, 5-1-46 calibrating, 8-2-1 fuse, 5-1-53 jumpers, 5-1-52 LEDs, 5-1-51 Terminal Block, Marshaling Panel Auxiliary, 5-1-57 termination panel Direct Discrete, 6-3-14 Direct Discrete II, 6-3-4 Discrete High Density Isolated, 6-3-41 Discrete Multi--FIM, 6-3-23 Isolated Discrete, 6-3-28 Standard Remote, 6-5-2 TERMINATOR CONTROLFILE BOTTOM, 4-1-7 test points Analog Transfer Card, 5-1-16 Battery Charger Card, 1-2-11 ControlFile 5 and 12 V DC Power Regulator, 4-2-16 5 V DC Only Power Regulator, 4-2-9 CP, 4-2-29 Isolated Analog Input FIC, 5-5-16 Isolated Analog Output, 5-5-29 Non--Isolated Analog Input FIC, 5-5-10 Non--Isolated Analog Output FIC, 5-5-24 NV Memory bubble, 4-2-52 RAM, 4-2-44– 4-2-46 OI NV RAM, 3-7-74 PeerWay Buffer, 4-2-4 Smart Transmitter FIC, 5-5-13 Thermocouple and Voltage FEM, 5-3-16 Thermocouple FEM, calibrating, 8-4-3 Index SV: Index-17 thermocouple sensor, redundancy, 8-2-7 TI 810 printer, 3-6-20 TI 960B, 7-5-6 TI Communications Card, 7-5-6 TIC, definition, 10-2-13 TIC Master, 10-2-13 Time Interval Controller. See TIC tool kit, 9-3-1 tools, recommended, 9-3-1 TOUCH PANEL, 3-1-10 Touchpad, 3-1-10 TOUCHPAD KEYBOARD, 3-1-13 Touchpad Keyboard Electronics Board, 3-1-13 tower electronics cabinet, 3-7-2 TP/8 Hub, 3-4-11 TRACKBALL 68HC05, 3-1-13 Trackball Assembly, 3-1-8 TRACKBALL KEYBOARD, 3-1-13 Trackball Keyboard, 3-1-8 Assembly, 3-1-8 cleaning, 9-1-5 Pedestal Command Console, 3-2-4 replacement subassembly, 3-1-8 replacing trackball, 9-1-5 Trackball Keyboard Electronics Board, 3-1-13 TRACKBALL SW MATRIX, 3-2-4 troubleshooting Analog I/O, 10-5-8 consoles, 10-3-1 ControlFiles, 10-4-1 fiber optic PeerWay cables, 10-2-42 Input/Output, 10-5-1 OI Card Cage problems, 10-3-24 PeerWay, 10-2-1 PeerWay Interface Devices, 10-6-1 power system, 10-1-1 Serial I/O, 10-5-3 Twinax PeerWay cables, 10-2-41 Twinax PeerWay, 2-1-1 cable, 2-1-9 termination, 2-1-11 troubleshooting cables, 10-2-41 Twinax PeerWay Tap Boxes, 2-1-3 twinaxial connector crimp type, 2-1-12 solder type, 2-1-12 Universal Voltage FEM, 5-3-16 UPS, 3-4-16 V Vacuum Cleaner, 9-3-2 VAX QBUS Interface, 7-4-1 VAX QBUS Interface Board 1, jumpers, 7-4-10 VAX QBUS Interface Board 2 jumpers, 7-4-13 LEDs, 7-4-15 VAX QBUS Interface Marshalling Panel, LEDs, 7-4-7 Video Generator Character Graphics, 3-7-42 Monochrome, 3-3-7 Pixel Graphics, 3-7-39 Viper 2060S, 3-5-23 2150S, 3-5-23 Voltage Input FEM, calibrating, 8-4-3 Voltage MUX Marshaling Panel, 5-3-7 VOLTAGE MUX MARSHALLING PANEL, 5-3-7 W Winchester disk drive. See hard disk drive Wipe Bubble procedure, 10-4-9 wiring color codes, 1-4-10 X X.25 protocol, 7-2-9 SCI, 7-2-9 cabling, 7-2-11 clocking, 7-2-13 U Y uninterruptible power supply, 3-4-16 Y cable, 5-3-3 RS3: Service Manual Index SV: Index-18 RS3: Service Manual Index