Fs 13500
Fs 13500
Service Manual
for use with the Honeywell FSC System
Releases 42x and 500
FS13-500
.
Implementation
FSC Safety Manager
FS13-500
02/98
Copyright, Notices, and Trademarks
TotalPlant, TDC 3000 and Universal Control Network are U.S. registered
trademarks of Honeywell Inc.
FSC is a trademark of Honeywell Safety Management Systems.
Other brand or product names are trademarks of their respective owners.
Honeywell
Industrial Automation and Control
Automation College
2820 West Kelton Lane
Phoenix, AZ 85023
(602) 313-5669
This publication is designed to assist you in servicing the FSC Safety Manager Module
(FSC-SMM) for use with the Honeywell FSC system Releases 42x and 500. Use this manual as a
guide for diagnosing faults and troubleshooting your system.
Please note that this document primarily focuses on the FSC Safety Manager Module. The entire
FSC-SM also comprises an FSC component, which has its own set of documents. Please refer to
these documents for more detailed information on the FSC part of the FSC-SM system.
Tables
Publication Publication
Title Number
FSC Safety Manual PM.MAN.8047
FSC Hardware Manual PM.MAN.8048
FSC Software Manual PM.MAN.8025
About this section This section contains a brief description and functional summary of the
FSC Safety Manager (FSC-SM), and provides hardware and software
requirements and dependencies. The topics included in this section are:
1.1 Overview........................................................................................................... 1
1.2 Hardware Dependencies .................................................................................. 6
1.3 Software Dependencies ................................................................................... 7
1.4 FSC-SM Installation and Configuration Checklist ............................................ 8
1.5 Specifications ................................................................................................... 9
Description, continued
LCN
NIM
PM
LM UCN A
S Central I/O
SM
UCN B M Part System
UCN M
FSC
Human interfaces As shown in Figure 1-1, two human interfaces are used in conjunction
with the FSC Safety Manager:
• the operator stations – i.e. Universal Stations (US), UXSs, Universal
Work Stations and Global User Stations – are configurations of the TPS
level user interface, and
• the FSC user station (with the FSC Development System or
FSC Navigator software), which interfaces with the FSC Controller.
Frontplate features As illustrated in Figure 1-2, the FSC-SMM frontplate includes the
following major features:
• Diagnostic and operation LED indicators, which indicate:
- the result of self-test diagnostics ('STATUS' LED),
- UCN transmit status ('Tx' LED),
- the primary (On) or secondary (Off) ('P' LED), and
- the UCN cable that is currently carrying message traffic
('A' LED / 'B' LED).
• F-style connectors, which provide a link to the redundant Universal
Control Network (A and B) via drop cables.
FSC
TM
STATUS
TX
P
A A
B
10008/2/U
Functional summary The FSC Safety Manager provides a dual redundant fault-tolerant
controller for safety and emergency shutdown applications on the UCN.
The two redundant FSC Control Processors collect, process and output
process information in parallel.
The control process accesses the I/O part via an I/O bus structure
consisting of a vertical bus, which interconnects the FSC Central Part rack
with the I/O racks. The vertical bus is controlled by the Vertical Bus
Driver (VBD) module. In redundant I/O configurations, each control
process has its own vertical bus to the I/O part, and has exclusive access to
that vertical bus. In non-redundant configurations, the control processors
share access to the I/O parts, via a single vertical bus.
FSC-SM architecture Figure 1-3 illustrates the dual-redundant architecture employed in the FSC
Safety Manager.
UCN
FSC-
Central SMM
FSC-
Central SMM
redundant
Part 2
redundant
input output
A B
Minimum equipment The following list gives the minimum pieces of equipment needed for a
required dual-redundant FSC Safety Manager system:
• one FSC user station, which is used to interface with the FSC
Controller. The user station has the following specifications:
− for FSC Development System software (DOS-based) (R42x):
a 386/486 IBM-compatible personal computer with 640 KB
RAM, 6 MB hard disk space, Hercules/EGA/VGA graphics,
and an HSMS 07177/1/. hardware key.
− for FSC Navigator software (Windows 95 based) (R500):
a Pentium-based IBM-compatible personal computer with
16 MB RAM (32 MB recommended), 15 MB hard disk space,
VGA graphics, and an 07177/1/. serial interface module (only
required if applications are to be programmed to EPROM).
• one TPS system including a Universal Station (US), a History Module
(HM) and a Network Interface Module (NIM), and
• as required, a Local Control Network (LCN), Universal Control
Network (UCN) and FSC communication cabling.
Figure 1-1 on page 2 shows the FSC-SM relationship to the TPS system.
Minimum software The software dependencies for the Safety Manager are:
releases
• the FSC system must be Release 420 or higher, and
• the TPS control system must be Release 530 or higher.
Summary The following checklist is intended to highlight the most critical steps in
the installation and configuration of an FSC Safety Manager.
Installation Checklist
Minimum Equipment ❑ two FSC Central Part racks.
Complement ❑ one or more FSC I/O racks (as required).
❑ one FSC user station, with FSC Development System software or FSC Navigator software.
❑ one TPS system including a Universal Station (US), a History Module (HM) and a Network
Interface Module (NIM)
.
❑ as required, Local Control Network (LCN), Universal Control Network (UCN) and FSC
communication cabling
.
FSC-SMM Installation ❑ Module installed on the configured position and cover screws fastened.
❑ UCN cables attached and torqued to specification.
❑ No UNAPPROVED right angle F-connectors used.
Configuration Checklist
DCS Addresses ❑ DCS addresses assigned to all FSC variables that will be used by the TPS application (DCS
addresses correspond to PLC addresses).
FSC-SMM ❑ Main processor module EPROMs burned and correctly placed on the main processor module.
Configuration ❑ Main processor application downloaded (optional).
❑ Communication processor module EPROMs burned and correctly placed on the communication
Downloaded / processor module.
Programmed ❑ FSC-SMM EPROM burned and correctly placed on the FSC-SMM
❑ FSC-SM started.
At this point, the FSC-SM should be ready for Node and Point Configuration at the LCN level.
Summary Refer to the FSC Safety Manager Specification and Technical Data
(FS03-500) for information on:
Summary The only spare part for the FSC Safety Manager system is the FSC Safety
Manager Module (FSC-SMM). Its HSMS part number is 3400144.
For assistance in ordering this part, cabling or any other FSC parts,
consult your Honeywell representative.
3.1 Overview....................................................................................................13
3.2 Soft Failures ..............................................................................................14
3.3 Hard Failures .............................................................................................16
3.4 Point Configuration Errors .........................................................................17
3.5 Communication Errors...............................................................................18
3.6 FSC-SMM Status Indicators ......................................................................27
3.7 FSC Diagnostic Information ......................................................................29
Summary Soft failures are situations where control and process view are maintained,
but a fault has jeopardized system integrity.
Softfail descriptions Table 3-1 lists the types of softfails that may be encountered.
19 UCNPRSFL Primary Cannot Talk FSC-SMM has lost the ability to communicate
to Secondary on UCN over the UCN.
20 UCNSCPFL Secondary Cannot Talk FSC-SMM has lost the ability to communicate
to Primary on UCN over the UCN.
63 LCIOCDFL LC Comm or I/O Card FSC System Aliases are signaling an I/O fault.
Fault
Soft failures US Figure 3-1 shows a US display which provides the various FSC Safety
display Manager soft failures and their corresponding error codes.
FSC-SM
STATUS
19 Primary Cannot Talk to Secondary on UCN
VERS/ 20 Secondary Cannot Talk to Primary on UCN
REVIS 21 Secondary Not Synched
34 UCN Overrun
FSC-SM 35 Point Processing Overrun
CONFIG 54 LC Not Scanning
63 LC Comm or I/O Card Fault
UCN 80 SMM Time Synch Failure
STATS 81 LC Time Synch Failure
MAINT
SUPPORT
SOFT
FAILURE
Hard failures Hard failures will result in FSC-SMM shutdown (to the FAIL state). Hard
summary failures include the following:
• component failure,
• program or database failure.
Crash codes Fail (crash) situations involve a large number of possible error codes.
Contact the Technical Assistance Center (TAC) for help in identifying the
causes of such failures.
Errors in configuring The FSC-SMM will only recognize LC aliases previously configured
points within the FSC. Table 3-2 lists configuration errors for the FSC Safety
Manager.
US display for Figure 3-2 is the US display which allows you to access the
communication Communication Error Block screen. To do this, you need to select the
errors target
"NODE STS INFO" target.
UCN
UCN PERSONALITY LOAD INFO
STATS
STATS NODE LOAD FAILURE INFO : 0
LOAD FLAGS : 40
MAINT
MAINT LOAD PACKET NUMBER : 914
SUPPORT NODE PERFORMING LOAD : 1
US display showing Figure 3-3 shows the US UCN statistics display which lists the various
UCN statistics UCN communication error statistics, along with other UCN statistics. The
values given are samples of what might be expected in a system which
operates correctly.
HELP RESET
RESET STATS
STATS
STATS PAGE 2
BOX
FSC-SM
STATUS NO COPY BUFFERS 0 TOTAL CABLE SWAPS 1
TOKEN ROTATION TIME 0 CABLE A SILENCE 0
VERS/
VERS/ NO SUCCESSOR FOUND 0 CABLE B SILENCE 0
REVIS ASKED WHO FOLLOWS 0 CABLE A NOISE 0
TOKEN PASSED FAILED 0 CABLE B NOISE 0
FSC-SM
BOX NOISE BITS 0 NO-RESPONSE ERRORS 0
CONFIG CHECKSUM ERROR 0 UNEXPECTED RESPONSES 0
REPEATER ERROR 0 ERRORS IN RESPONSES 0
UCN
UCN PARTIAL FRAME 0 AUTO-RECONNECTS 0
STATS
STATS
STATS RECEIVED FRAME TOO LONG 0
NO RECEIVE BUFFERS 0 LOCAL MESSAGES 0
MAINT RECEIVE OVERRUN 0 MESSAGES SENT 306
SUPPORT DUPLICATE RWR 0 MESSAGES RECEIVED 122
NULL RWR (RESYNCH) 0 MESSAGES DISCARDED 0
SOFT TRANSMIT UNDERRUN 0 REPLY TIMEOUTS 0
FAILURE TRANSMIT FRAME TOO LONG 0
Local UCN statistics Table 3-3 describes each of the local UCN communication error statistics
description listed in the example US display in Figure 3-3. It also gives a probable
cause or probable causes for why each error might occur.
No Copy Network Interface Ideally, should be zero (0). Increases when the NIM is
Buffers Module (NIM) only; no congested.
buffers in the Events are throttled to reduce the
processor to copy probability of errors; the event
received messages. recovery logic will ensure events
are up-to-date.
Token NIM only; the average Depends on number of configured Increases when the node is
Rotation network token rotation nodes that are on the network offnet or the UCN node
Time in 0.1 millisecond (e.g. for a six node UCN network, addresses have gaps. Also
units. the nominal range is between 4-5 increases with more traffic.
ms). When running smoothly, the
user should record the nominal
range of his/her system for
comparison.
No The token ring Should be zero in systems with Fewer than two token
Successor collapsed. two or more nodes passing tokens passers, a network
Found and no communication problems. communication problem.
Noise Bits Noise detected. 1 count per 10 seconds is typical; Communication fault,
the lower, the better. Messages grounding problem.
Retried count does not necessarily
imply lost messages.
Partial Frame Full message not Should be zero in a smooth Communication fault.
received. system.
The message is retried.
Received Message received Should be zero. Has not yet been observed.
Frame Too > 1 KB. Software bug.
Long
Total Cable The sum of all swaps: Once every 15 minutes when Periodic cable swap
Swaps operational, automatic there are no faults, noise or enabled.
and periodic. silence present.
No- One or more node did Should be zero in a smooth Node(s) offnet, node(s)
Response not respond to an system with all nodes on net and overloaded.
Errors RDR. properly configured.
Unexpected MAC control incorrect Should be zero. LLC bug or contention (more
Responses in RWR. than one node believes it
has the token).
UCN STATS display, Figure 3-4 shows an example of page 2 of the UCN STATS display. You
page 2 can access this screen, from page 1 of the UCN STATS display, by
selecting the STATISTICS PAGE TWO target.
HELP RESET
RESET STATS
STATS
STATS PAGE 1
BOX
FSC-SM
STATUS EVENT SENDER STATISTICS
MESSAGES SENT 3
VERS/
VERS/ MESSAGES RETRIED 0
REVIS RECEIVER DROPPED 0
NAKS RECEIVED 0
FSC-SM
BOX THROTTLING REQUESTED 0
CONFIG NUMBER OF EVENT RCVRS 1
UCN
UCN TIME SYNCH STATUS TIME SYNCH STATISTICS
STATS
STATS
STATS UCN DATE 10 Jun 97 SYNCH ERRORS 0
UCN TIME 14:27:31 LOST MESSAGES 0
MAINT SYNCHER NODE 1 CLOCK ERRORS 0
SUPPORT CURRENT STATE OK DRIFT THRESHOLD 0
DRIFT VALUE 0
SOFT
FAILURE
Event sender UCN Table 3-4 describes each of the event sender UCN communication error
statistics description statistics listed in the example US display in Figure 3-4. It also gives a
probable cause or probable causes for why each error might occur.
Receiver The number of times Zero in NIM, one in FSC-SM if NIM shutdown, NIM failure,
Dropped an event receiver did there is a NIM failure. NIM congested.
not respond after
retry.
NAKs Message not Should be zero except under Heavy event load.
Received accepted by receiver. heavy event load.
Throttling The number of times Should be zero except under Heavy event load.
Requested the node was heavy event load.
requested to delay
before sending the
next message.
Time synch statistics Table 3-5 describes each of the time synchronization error statistics listed
description in the example US display in Figure 3-4. It also gives a probable cause or
probable causes for why each error might occur.
Time synch status Table 3-6 describes the time synchronization status portion of the example
description US display in Figure 3-4.
LCN Time Reflects LCN time within the FSC-SMM. The time is accurate to ± 1 second.
Current State The time synch state of this node. A PNI NIM or an NIM with time synch disabled will
report "Failed."
UCN addressing An FSC Safety Manager UCN address is configured at the FSC user
errors station using the FSC Development System software or FSC Navigator
software. Range checking within the FSC user software is assumed (1-63,
odd addresses only). The top/bottom module placement within a given
slot determines top/bottom shadow addressing. It is therefore impossible
for an FSC-SMM to operate with an invalid UCN address. However,
there is no protection against duplicate use of a UCN address.
Status indicators The front panel of the FSC-SMM includes components which provide
status information (see Figure 1-2). The front panel includes:
• a (red/green) 'STATUS' LED, and
• four additional (red) LEDs.
If the 'STATUS' LED is green, the four small LEDs provide additional
information about the UCN communication:
• The 'Tx' LED is on when data is being transmitted.
• The 'P' LED is on when the node is primary (and off when the node is
secondary).
Note:
If the node is not redundant, the 'P' LED will always be
off.
Status indicators, If the 'STATUS' LED blinks green/red, counting the number of times
continued that the LED turns green provides diagnostic information on the error that
has occurred. (Stop counting when the LED stays red for about four
seconds.)
Table 3-7 lists the number of 'green flash' counts with their associated
errors.
12 Command timeout
20 TBC interrupt
FSC diagnostic The FSC system provides extensive diagnostic information about the
display operating status of its system components. Any faults are reported in the
FSC Diagnostic Display at the US (see Figure 3-5). It will show a
description of the component(s) affected, together with their module
number and exact location (rack, position), as well as the date and time
that the fault(s) occurred.
The FSC Diagnostic Display can be called as follows:
1) From the System Status (SYST STATS) screen, select a valid LCN
node.
2) Select the NTWK/HWY STATUS (Network/Highway Status) target.
3) Select the UCN node you want diagnostic information about.
4) Select the DETAIL STATUS target.
5) Select the FSC DIAG target.
SM DETAIL MAIN
BOX STATUS - FSC DIAGNOSTC DISPLAY - Page 1 of 5 << PAGE >>
SOFT
FAILURE HARDWARE FSC PROGRAM FSC DIAG
About this section This section provides instructions and references for the removal and
replacement of the FSC Safety Manager Module and its components. The
topics included in this section are:
Subsection Topic See Page
4.1 Overview....................................................................................................31
4.2 Replacing an FSC-SMM............................................................................32
4.3 Replacing the Firmware EPROMs ............................................................34
4.4 FSC-SMM Slot Keys..................................................................................36
Replacement of the Table 4-1 describes the procedure for replacing the FSC Safety Manager
FSC-SMM Module (FSC-SMM).
2 Shut down the Central Part that contains the FSC-SMM you
want to replace, by disconnecting the flatcable of the
10005/./. watchdog (WD) module of that Central Part. After
shutting down the Central Part, make sure to reconnect the
watchdog flatcable.
4 Shut off the power to the Central Part by switching the circuit
breaker which controls the power to that Central Part.
8 Carefully insert the new FSC-SMM into the Central Part rack.
9 Secure the FSC-SMM at the top and bottom using the two
screws that were removed in step 6.
Replacement of the
FSC-SMM, continued
Table 4-1 – Procedure for FSC-SMM replacement (continued)
13 Wait until the 10006/./. Diagnostic and Battery Module (DBM)
starts updating the time. Then turn the keyswitch on the
10002/./. Central Processing Unit (CPU) module back to the
RUN position (vertical).
Introduction EPROMs contain the firmware version currently being used in the FSC
Safety Manager system. Each EPROM has a label which provides the
following information:
• EPROM type,
• software revision number, and
• module serial number.
Refer to the FSC Hardware Manual for details on the location of the FSC
firmware at the 10002/1/2 Central Processor Module and 10004/./.
Communication Module.
Slip the strap on your wrist like a wristwatch and connect its clip to the
ground bus, which is located inside the cabinet. There is no danger of
receiving a shock from an approved wriststrap.
FSC firmware upgrade Table 4-2 describes the procedure for upgrading the FSC-SMM firmware
EPROMs.
Summary Each FSC slot is fitted with metal keys at the top and bottom so that only
one particular type of module fits in that slot.
• If you ordered the FSC Safety Manager Module at the same time you
ordered a new FSC, the keys are correct and no action is required.
• If you ordered the FSC-SMM separately, then you have to replace the
keys.
A F, G
A LED, 3, 27 Failures
Asked Who Follows, 20 Hard, 16
Auto-Reconnect, 22 Soft, 14
Firmware EPROMs, 34
Frontplate features, 3
B FSC Development System, 6
FSC diagnostic display, 29
B LED, 3, 27 FSC firmware upgrade, 35
FSC Navigator, 6
FSC-SM architecture, 5
C FSC-SM functional summary, 4
Cable A Noise, 22 FSC-SM Installation and Configuration Checklist, 8
Cable A Silence, 21 FSC-SMM replacement, 32, 33
Cable B Noise, 22 FSC-SMM status indicators, 27
Cable B Silence, 21 F-style connectors, 3
Checksum Error, 20
Clock Errors, 25
Communication Error Block screen, 18 H
Configuration errors Hard failures, 16
CONFIGURATION MISMATCH, 17 Hardware, 6
ILLEGAL VALUE, 17 Human interfaces, 2
READ ONLY, 17
CONFIGURATION MISMATCH, 17
Crash codes, 16
Current State, 26
I, J, K
ILLEGAL VALUE, 17
D
Duplicate RWR, 21
L
LCN Date, 26
LCN Time, 26
E LED indicators, 3, 27
LEDs
Electrostatic discharge (ESD), 34 A, 3, 27
EPROMs, 34 B, 3, 27
Error codes with 'STATUS' LED flashing, 28 P, 3, 27
Errors in configuring points, 17 STATUS, 3, 27, 28
Errors In Responses, 22 Tx, 3, 27
Event sender UCN communication error statistics Local Messages, 22
Messages Retried, 24 Local Token Rotation Time, 20
Messages Sent, 24
NAKs Received, 24
Number Of Event Rcvrs, 24
Receiver Dropped, 24
Throttling Requested, 24
T U, V, W, X, Y, Z
Throttling Requested, 24 UCN addressing errors, 26
Time synch status UCN communication error statistics, 19
Current State, 26 UCN statistics display, 19
LCN Date, 26 UCN STATS display, 23
LCN Time, 26 Unexpected Responses, 22
Syncher Node, 26 Upgrading the firmware EPROMs, 34
Time synchronization error statistics US Display – Soft Failures, 15
Clock Errors, 25 US display for communication errors target, 18
Lost Messages, 25
Synch Errors, 25
Token Passes Failed, 20
Total Cable Swaps, 21
Transmit Frame Too Long, 21
Transmit Underrun, 21
Tx LED, 3, 27
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