TDC 3000 TAB CUSTOMER PAGE RESOURCE MANUAL DATE PD17 INDEX 1 31 DEC 1995 17. TDC 3000 REMOTE USER LAN ACCESS (RULA) ‘A. RULA MANUALS 01. Manuals ‘A. TAClink Manual B MODEMS 01. Parameter Settings ‘A. Motorola Codex 3260FAST V.34 Modem Set up Moneywell Inausteial Automation ana ControlTDC 3000 TAB PD17 CUSTOMER PAGE ‘A01 (A) RESOURCE MANUAL DATE 2 DEC 1996 TAClink Manual Remote User LCN Access (RULA) Link to the Technical Assistance Centers Copyright, TDC 3000* is a trademark of Honeywell Inc. Notices, and Trademarks CenterCOM is a registered trademark of Allied Telesis Inc. Cisco is a trademark of Cisco Systems, Inc. Codex is a trademark of Motorola Corporation Comsphere is a registered trademark of AT&T Paradyne Corporation Dayna, DaynaPORT SCSI/Link-3 and DaynaPORT are trademarks of Dayna Communications, Inc. UNIX is a trademark of AT&T Corporation Xyplex is a registered trademark of Xyplex, Inc. All address and phone numbers contained in this document are in the U.S.A. Continued on next pageTAB PD 17 AOt (A) PAGE _2 DATE _2 DEC 1996 TAClink Manual, Continued Table of Contents Sect. Description Pg. 1 Summary Information. 3 2 TACIink Disclaimer.. 6 3 TAClink Hardware 7 4 TAClink Software and Displays 9 5 TAClink Troubleshooting 15 6 — Appendix A - Third Party Company Information .. 18 7 Appendix B - Bill of Materials .. 19 Figures Figure Description Pg. 1 Logical View of RULA.. 3 2 TAClink Block Diagram: 5 3 RULA TAClink Hardware 7 4 RULA Site Configuration Display 10 5 RULAControl Display.. "1 6 — RULA Status 2 Display 12 7 RULA Error Statistics Display 13 8 Quick Disconnect from Keyboards 14 9 Hardware Troubleshooting .. 17 Tables Table Description Pg. 1 Procedures for TAClink 5 2 17 3 19 4 19 Continued on next page Moneywell induseriad automation and Control‘TAB PD 17 AO1 (A) PAGE _3 DATE _20 JUN 1995 TAClink Manual, Continued 1. Summary Information Overview This manual summarizes the necessary equipment, configuration, and general information on how to establish a Remote User LCN Access (RULA) link with Honeywell Technical Assistance Centers (TACs). Extensive reference to other manuals is used since the more specific steps have already been explained in these manuals: RULA Specification and Technical Data — RLO3-400 RULA User Manual MP-RLSWOt TAClink provides TAC with a “window” which allows inputs into a customer's LCN system by using RULA hardware and software to help accomplish remote diagnostics and troubleshooting. RULA allows the customer (user) with a station on the LCN to transmit the screen displays both locally to the Host station, and to the Remote station at TAC. TAClink utilizes bridges and modems using standard telephone lines. Itis secure because it uses, isolated Ethernet segments at both ends and access to the Host LCN system from the Remote US can be disabled (more on security follows throughout this manual). No TCP/IP (Transmission Control Protocol/Internet Protocol) is used in TAClink. A logical view of the RULA system is shown below. Remote Site (e.., Central Engineering, TAC, etc.) Figure 1 - Logical View of RULA ‘Continued on next page Moneyvell Industrial Automation ané Control‘TAB PD 47.01 (A) PAGE _4 DATE _20 JUN 1995 TAClink Manual, Continued Definitions The Host Site is the site that has view and control to the process as well as to the other nodes on its LCN throughout the RULA session. The Remote Site is the site that views the Host’s LCN system and the Host’s process. When using TAClink, TAC will be the Remote Site. Input from TAC will be through the Remote station’s keyboard and touchscreen (unless it is disabled). The Universal Station (or U*S, or UWS, or Micro TDC3000%) is mandatory for the operation of RULA. RULA is not available for any other LCN node type. RULA specifically requires Universal Personality to operate on release R430 or later. Notes: The Engineer Keyboard is necessary for use of the RULA emergency disconnect key sequence. The US only transfers the LCN Native Window. The SCSI (Small Computer System Interface) protocol requires an EPDG or TPDG (for the U*S) peripheral board. These boards are mandatory for the operation of RULA, as it allows operation of the converter unit with the station. A local Bernoulli Cartridge Drive (20MB or 150MB) is also required for file transfers and SCS! bus communications to the converter unit. The Converter unit refers to the DaynaPORT SCSI /Link-3 device (or DaynaPORT for short), which is mandatory for the operation of RULA. It is the device that allows the station to send and receive station peripheral (for example, screen, keyboard, and touchscreen) data and instructions. It outputs onto a standard Ethemet cable and receives ‘on the same cable. It is a SCSI to Ethemet protocol converter. The Ethernet cable is mandatory for the operation of RULA and provides the means for transmitting data using the IEEE 802.3 protocol to bridges. Tees and 50 ohm terminators are also required. For TACIink, a thin Ethemet cable (10Base-2, RG5S8-A/U) is preferred. TAClink uses specific bridges which have been certified to work properly with the RULA software. The bridges are required and allow the RULA packet information to flow to the modem in an uncompressed or compressed mode, the latter being more efficient. The type of bridges certified for use with TAClink are described in Section 3, TAClink Hardware. The bridges use PPP (Point-to-Poin') protocol to pass (or bridge) the data across to the other network (the isolated Ethemet setup for RULA at the other end). Continued on next page Moneywell industriel Automation and ControlTTAB __PD 17 A01 (A) PAGE _5 DATE _20 JUN 1995 TAClink Manual, Continued TAClink Block —_Since TAClink uses standard telephone lines, two Modem devices are also Diagram needed for the operation of RULA, one at each end. The minimum allowed baud rate that the modem speed can be set for a RULA connection is 9600 bps, but when using the compression software in the bridges, even this ‘speed yields good screen update results. The types of modems certified for use with TAClink are described in Section 3, TACIink Hardware. To ensure that the information being passed between the user and TAC is ‘secured, an isolated Ethernet segment is required at both ends. We recommend that two transceivers (MAU - Media Access Unit) be used to protect the DaynaPORT and the bridge. See Figure 2 below. A summary of TAClink procedures are listed in Table 1. "ATTENTION \When connected to Honeywell TAC a RULA sation shouldbe isolated to an Ethernet tegent ccaed BULA Cy. Ccumeme te me maa Ran ‘Station Mose [=F oem Station BaraPORT] — [aaporoner [eecxrom | [Peace ey ‘oloted Ethemet cables with terminators at each end of the cables. Figure 2 - TAClink Block Diagram Table 1 Procedures for TACIink Procedures ‘Step ‘Action/Result Install RULA mounting kit, cables, bridge, and modem. ‘Change NCF and reload station with RULA software. Call a TAC Engineer to test TACIink or when a problem arises. Call TAC modem and establish a good phone connection. Enable diagnostic testing and connect RULA. if diagnostic tests are successful: disconnect RULA, disable diagnostics, and connect a normal RULA session to test further ‘or work a problem with a TAC Engineer. 7 _ | If diagnostic tests are not successful then troubleshoot RULA software and hardware installations until tests are successful. & _ | After testing or working problem with TAC Engineer disconnect RULA, then the modem, then hang up with the TAC Engineer. | | a] o] ro] ‘Continued on next page Honeywell industrial Automation and Control‘TAB __PD17A01 (A) PAGE _6 DATE _20 JUN 1995 TAClink Manual, Continued 2. TAClink Disclaimer Disclaimer ‘The RULA and DaynaPORT disclaimers can be found in the RULA User Manual, Section 1.0 and the RULA Specification and Technical Data manual, Page 2. In addition, the use of the RULA TACIink to TAC becomes the full responsibility of the user at the Host end. As such, the user must constantly monitor during the entire RULA session what the TAC Engineer does or does not do to the Host LCN System. If the user wants to disable all inputs from the Honeywell TAC center, there are targets available at the initial RULA display after the connection is made to disable the Remote (TAC) station’s keyboard and touchscreen. In this fashion, the TAC Engineer becomes an observer of the displays being called up from the Host site. ‘There is also a quick disconnect feature to end a RULA session if at anytime the user wants to break the RULA connection. This requires an Engineer's keyboard. See Section 4 for more detailed information. Continued on next page oneyeell Industrial Autonation and Control"TAB __PD17A01 (A) PAGE _7 DATE _20 JUN 1995 TAClink Manual, Continued 3. TAClink Hardware Mounting Kits Block diagram AKALCN (or K4LCN in R500) board is required in the station at the Host site for faster processing and a 68020 processor board at TAC. There are four different RULA mounting kits to allow a station to mount the DaynaPORT required to use RULA. These are kits MP-RLKTO1 through 04 for the US, Micro TDC3000%, U*S, and UWS (in that order). The kits include various cables, mounting hardware for the DaynaPORT, and instructions. Always have power off to the station and cartridge drives and use ESD protection when installing RULA kits. ‘As shown in Figure 3, each RULA station connects from the EPDG or TPDG board, through the cartridge drives, to the DaynaPORT. The cartridge drive ‘SCSI ribbon cable is removed and the RULA kit's SCSI ribbon cable, supplying an extra connector for the DaynaPORT, is installed. The cartridge drive terminators are removed from the last cartridge drive on the SCSI bus since the DaynaPORT provides the terminator to the SCSI bus internally, ‘The address of the DaynaPORT on the SCSI bus is 4, and must be dialed on the DaynaPORT’s SCSI ID switch. A RULA SCSI bus adapter cable then connects to the SCSI bus ribbon cable and to one end of the DaynaPORT. The power supply to the DaynaPORT is provided from the cartridge drive. The AUI (Attachment Unit Interface) cable then connects to the other end of the DaynaPORT and then to a transceiver, which connects to a tee on an isolated Ethemet cable (should be a thinnet cable) with 50 chm terminators at both ends. At the other end of the isolated Ethernet cable a tee connects to a transceiver, and then to the bridge, which then connects to the modem with a 25-pin RS232 serial cable (from the Xyplex bridge) or a RS232 DTE cable (from Cisco, P/N:72-0793-01). The modem then connects to the telephone line. The DaynaPORT, transceivers, the Ethernet thinnet cable, tees, terminators, the bridge and the modem with the RS232 cable are not supplied in the RULA Kit. a gansta * ce DayraPOAT a) er sede ual eT LA 7 nies or ecSris ceoetf >] Tanacover | Transcsnert—— 2998!" ose ‘Staton L156 Sic enamel |p mA Roser Powe | enemet Cable * soot [EG ase] PREAPORT "|g naa] WAT seSttnk's aw 5] Unveral or Trancover[ ransoier- 22 86001 | ode Sr | to ll oesicene a ee * Not Provided by Honeywell with Standard RULA Preduct Figure 3 - RULA TAClink Hardware ‘Continued on next page‘TAB PD 17 A01 (A) PAGE _8 DATE _ 20 JUN 1995 TAClink Manual, Continued Bridges Modems There are two types of bridges that have been certified for use with TACIink. ‘The preferred bridges are from Xyplex. There are three models that were certified, the 6220, 3401 and the 3801 bridge/hub, the two latter ones being the newer N3000 models. The reason they are the preferred bridges is because TAC can provide the users with the proper configuration on a 3 1/2 “floppy, which should be inserted before the first time that power is applied to the Xyplex bridge (critical for the N3000 models), making it very convenient to use. For greater efficiency, Xyplex software 5.x or later is required at both ends to pass compressed data. The other certified bridge is a Cisco 2501 with 10.x software or later, or any Cisco bridge/router programmed as a bridge with the proper configuration and software of 10.x or later (refer to the RULA User's Manual, Section 1.11 on how to configure using a UNIX terminal to use Point-to-Point protocol). Cisco software version 10.3 or later is required for data compression. ‘The WAN (Wide Area Network) is not used in a TACIink (in Figure 3). Instead, a normal telephone connection between the modems is used. ‘There are two acceptable modems certified for TAClink. The first is the AT&T Paradyne Comsphere 3830, which can be difficult for the user to program. The telephone numbere are entered through the use of a PC. (Personal Computer). A much more user friendly modem is the Motorola Codex 3260FAST modem, which can transmit at speeds of up to 28.8 Kbps (uncompressed data). Section 1.9 of the RULA User's Manuals has the steps necessary to program this modem the first time, so it can be used over and over again with the same configuration (however, itis very easy to add a new telephone number to its memory or to temporarily use a different telephone number through its buttons and LCD display). Refer to the RULA User's Manual, Section 1.9, on how to program the Motorola Codex 3260FAST modem. ‘The main Phoenix TAC telephone number to talk to a TAC Engineer is. 602/313-5558, The RULA telephone number is 602/313-5131. Other RULA telephone numbers may be used. Please note that if a bad telephone connection is experienced during a RULA session, the user should disconnect (hang-up) the line at the modem and redial the TAC RULA modem telephone number. Establish a phone connection with a TAC engineer before making the modem connection. It is necessary to establish a good modem communications before trying to connect RULA with TAC. Section 4 explains making the RULA connection. Continued on next pageTAB __PD 17 A01 (A) PAGE _9 DATE _20 JUN 1995, TAClink Manual, Continued 4. TAClink Software and Displays Purpose Warning Configuration Loading Station Definition ‘A RULA cartridge (one per LCN, P/N: MP-RLSW01) is provided after purchasing a RULA kit. It contains the External Load Module software file necessary to run RULA (RULAUP.LO in the &CUS directory). It also contains two files to customize the RULA Site Configuration Display. The other RULA display files are supplied in the standard &DSY directory in the &C2 cartridge with R430 software or later (Note: A R43x station cannot communicate across RULA to a R5xx station). An EC file in &C2 cartridge under the &EC directory (RULA.EC) is supplied to copy the necessary RULA files from the RULA cartridge to the History Module (NET). If you already have made modifications to the RULA Site Configuration Display (SRULACFG.DS), save a copy someplace else in your HM or spare cartridge, since the EC may overwrite it (if the EC prompts are answered incorrectly) with a default display from the RULA cartridge. ‘ACF modification to the station is required to be able to load the RULA software in the station’s memory. If other External Load Modules are Present in the second page of the station, and the TOTAL memory amount is greater than 100,000 words after adding RULA and running the NCF Checker (F1), more memory is needed in the station (or remove one or more of the other custom software modules from page 2 of the NCF). Please follow the steps in Section 2.1 and 2.2 of the RULA User's Manual on how to properly add RULA to your site. Minimum memory required for Universal Personality is 4MW in Raxx, 6MW in R5xx and 8MW for U"S. After running the RULA.EC file and modifying the NCF, the station can be shut down and reloaded from NET, or from cartridges (&C2 and Customer NCF, which includes current files in &ASY and &CUS, with the RULAUP.LO file). At the U“S, use the hard disk drive for the personality and NET for the rest of the software. Recall the Console Status Display after the station is loaded to get the RULA CONTROL target at the bottom. As a security feature, it is necessary to have the station's keylevel to the ENGR (Engineer) level to see this target. Before going further, two more RULA display definitions are necessary: LOCAL means the station you are sitting in front of. OTHER means the station on the other side of the RULA connection. ‘Once the RULA CONTROL target has been selected for the first tme, the RULA Site Configuration Display will appear. Continued on next pageTTAB __PD17A01 (A) PAGE _10 DATE _20 JUN 1995 TAClink Manual, Continued RULA Displays On the RULA Site Configuration Display (see Figure 4), the user selects at the bottom target labeled READ DEV ADR to read the DaynaPORT’s, Ethemet address (Ethernet ID on the display). The other entries on this line are optional. Selecting the SITE DESC target under the Local Site Information and selecting the line below with the information you entered for the DaynaPORT address will bing the address to the top of the display in the proper place. Select the ETHERNET target at the bottom and then enter in the TAC DaynaPORT address (Phoenix: 008019100812, but can be different depending on which TAC station is available). Select SITE DESC under the Other Site Information. Selecting the line below where the TAC DaynaPORT Ethernet address was entered will bring the TAC DaynaPORT address to the top. Next, at the user's site, under the Local Site Information the target NODE STATE should be selected once, so that the user's Local site becomes the HOST. At TAG, the opposite addresses are entered into the TAC station for Local site and Other site and the TAC Engineer would select twice the NODE STATE under the Local Site Information (Local to the TAC Engineer) so that REMOTE would show up for the TAG (Local) station and HOST for the user's (Other) station (similar to “mirror images"). ‘Alter selecting the Dynamic Site Definition tne, the site Te mar oasis a Renote User Yen access - Site Configuration O1spiay ‘ener site Inforastion Site 10 Node State: Ethernet 10 + Internet 10 + Site 10. Etnernet 10 Internet 10, Site cefinition EI TOR ‘cas owomwowor © coososoocor | CONTROL se sescrorn TT CE Losey ‘Select the line of ste configuration defined under Dynamic Site Defnion, Figure 4- RULA Site Configuration Display ‘Continued on next page Woneyweli Industrial Automation and ControlTAB PD 17 AOt (A) PAGE 11 DATE _ 20 JUN 1995 TAClink Manual, Continued Caution After the RULA Site Configuration Display has been configured, the target at lower right, RULA CONTROL DISPLAY, can be selected. On the RULA Control Display (Figure 5) the top target contains some of the information that was entered on the RULA Site Configuration Dispiay. The target below that and in the middle, intially says CONNECT RULA. To the right of this target there’s another target labeled DIAGNOSTIC DISABLED. To the right bottom of the display other targets appear to call up RULA ‘statuses and statistics displays. The Configuration Access Restrictions targets (at bottom left) do not intially appear. They are displayed after a normal RULA session is established. This is where the user's Host station can disable the TAC’s Remote station keyboard and touchscreen, making the Host LCN entirely secured from outside inputs. Disabling both the Host and Remote stations’ keyboards and touchscreens renders the stations useless, and they would both have to be reset and reloaded to resume operation. “Target to inate Ping, Forcing Generation of Ethernet Trac FFargat to Call Up RULA] ‘Screen indcation of Site Configuration ‘Active RULA Session Display Y_Batete User LON Aecnes = contro otsptay Tocat$Tte+ SITE DESCRIPTION WORT DENG STER T SITE DESCRIPTION WOT mrs 1 Site1D : 10.8 2 State + HOS Node State: REOTE y orscnostae Disconnect RULA ‘Orsanceo, wo eenoe Cone = Host moe ROR status 1 enaaceo 7 fock RUthor ty 2 MOST status 2 TT Sues rh \ 4 Configurable Access Restrictions. RULA can be disconnected Targets to Call Up_ using this target or the ek | | Troubleshooting Gisconmectiey sequence. || and Status Displays Figure 5 - RULA Control Display Continued on next page Moneywe2l Industria? Avcomation and Conerel|TAB __PD 17 A01(A) PAGE _12 DATE _20 JUN 1995 TAClink Manual, Continued Diagnostic Before selecting the CONNECT RULA target on the RULA Control Display, ‘TAC recommends you first run diagnostic tests to see if the hardware is. installed correctly. At both the user's and TAC’s stations the target labeled DIAGNOSTIC DISABLED should be selected so it would change to DIAGNOSTIC ENABLED. Then within one minute the CONNECT RULA target must be selected at both stations. The stations send test PING messages continuously to the other RULA station until the DISCONNECT RULA target is selected. On the RULA Control Display the date/time line goes to one half size text and reverse cyan background, and RULA DIAGNOSTIC appears below it in reversed yellow. ‘Above the CONNECT RULA target the message: Warning - Connection of Diagnostics in Progress, will lash. If the PINGs get through and the other station PINGs you back, you'll get for the Communication Status: Diagnostic Success. If you get the message: Diagnostic Timeout, wait a few minutes before selecting the DISCONNECT RULA target and trying again. If you keep’getting Diagnostic Timeout, you should troubleshoot the hardware (Section 5). Before or while diagnostic tests are running, at the user's Host LCN, call up the RULA Status 2 Display ($RULAST2) on another station, selecting at the lower left the NODE NUMBER target, and entering the node number for the RULA station (see Figure 6). ‘Pgs bang done nine size nccated by Gomm Size] [Pings recone by ne etanon ae |e emcee RUA DAOHOSTIC Pros Set ee 5 wonser| [satus centre | suse x) foot wuec Boe Pre tineou | [caetofuneves ence] [MeSremandMiriman | | Figure 6 - RULA Status 2 Display Continued on next page oneyweli Industria? Automation end ControlTAB __PD 17 A01 (A) PAGE _13 DATE __20 JUN 1995 TAClink Manual, Continued Diagnostic, Continued Errors On the RULA Status 2 Display, while trying to make a connection, or if a connection has already been made, the HOST column of the display should be updating at the user’s Host site (the values are reset automatcally at the start of a RULA connection). At the bottom of the display, labeled Diagnostic Statistics, the first two entries, Diag. Msgs. Sent and Diag. Msg. Acks. should be increasing. These are PINGs being sent and acknowledges being received at the user’s Host station. On the previous section on the display, ‘two lines up and to the left, there’s an entry for Comm. Rate Delay. This is the delay that RULA is experiencing probably because of a bad telephone connection between the modems. In TAC’s experience, if this number does not go below 30 within a few minutes after a RULA session has been established, call up of schematics and file manipulation may take a long time. It may be beneficial to disconnect RULA, and then the modem, and redial TAC. This value can also be low at the beginning and go way up (over 100), to the point that nothing can be called up in a reasonable amount of time or the modem drops the line automatically. In the Error Statistics Display ($RULAERS in Figure 7) the crucial value to also look at is called Frame Retransmits. It should have a low value (below 30) and not be incrementing after the RULA connection. If it does increment, and the Comm. Rate Delay keeps going up, another modem connection should be tried. Node #82 Reaote User LON Access - Error Statistics OLepIay Tao Wear bytes Sent 5284 gytes Receives "S428 Pranee Sent 62 Frases Receives 7 BULA Franes Sent 123 RUUR Frases Rec" 124 Connect statue genore Tote! Errore Unrecognized nsgs ICNP Pan Ervors Tineoute ICRP re Guenens Ten? Reatr Megs Dverrun Events Duplicate windows Retranesite high Eres. oneywell Industrial Automation and ControlTAB __PD 17 A01 (A) PAGE _14 DATE _20 JUN 1995 TAClink Manual, Continued Errors, Continued Normal RULA. Session If the message “Diagnostic Success is seen in the RULA Control Display (Figure 5) for the Communication Status line, you're ready to proceed to connect a normal (non-diagnostic) RULA session with TAC. To end the diagnostic tests, the user and TAC should select the DISCONNECT RULA target. The date/time line retums to normal format and the target toggles back to CONNECT RULA. Both sides should then select the DIAGNOSTICS ENABLED target so that it toggles back to DIAGNOSTIC DISABLED. Then both sides should select the CONNECT RULA target within one minute of each other. This should establish a normal RULA ‘session after 10 to 30 seconds. The flashing in the middle of the display would appear again with the appropriate message and if successful, the date/time line goes back to one half text, and the words RULA SESSION HOST (at the user’s Host station) will appear below it in reverse background yellow. The Communication Status should say: No Errors. The Configurable Access Restriction targets would then appear (Figure 5). When finished, disconnect RULA, then the modem (push “RETURN” on the Motorola Codex 3260FAST), then hang up with the TAC Engineer. ‘Anormal RULA session would last until either the DISCONNECT RULA target is selected, or a quick disconnect is performed, or a modem drops the line. To quick disconnect and end the RULA session immediately on the Engineer's keyboard the CTL and the 5 in the keypad have to be pressed simultaneously (at either end). For the U’S, the keys are CTL and - (minus) on the keypad (see Figure 8). It will take several seconds to return the stations for normal use. Figure 8 - Quick Disconnect from Keyboards Continued on next pageTAB PD 17 AOt (A) PAGE _15 DATE 2 DEC 1996 TAClink Manual, Continued 5. TAClink Troubleshooting ‘Software Hardware If the RULA diagnostic times out each time you try it, and a normal RULA session cannot be established, troubleshooting is in order. Items to check in the software are as follows: * Make sure that the RULA station is loaded with R430 software or later by calling up SMCC Maintenance target from the Engineering Main Menu, Rev/Config Status, entering the node number for the RULA station, and reading the bottom line, which should say 43.xx for R43x (or 5x.xx for 5x). Remember: a R43x station cannot communicate across RULA with a R5xx station. * Call up schematic CBREV (supplied in the &C6 cartridge under the TLK1 directory) and make sure that RULAUP software is loaded in the station (if not, check the &CUS on the NET for the RULAUP.LO file, copy from the RULA cartridge if missing and reload the station). Also check the station’s node configuration and make sure that RULA is configured in the External Load Modules (second page of the NCF for the US). © Verify that both DaynaPORT Ethernet addresses are correc: on the RULA Site Configuration Display by reading the addresses from both DaynaPORTs again. As for the hardware. there are more items to check. All the steps are clearly stated in the RULA User's Manual, Section 6.4. Always try disconnecting and redialing the TAC modem first. if the RULA mounting kit installation instructions were followed carefully (check all connections again), most of the errors found are from bad telephone lines. Redialing may get a better phone line (may have to repeat several times). If reliable RULA connections are not possible after several tries, you may want to limit the maximum speed of the modems to 19.2 Kbps cr 14.4 Kbps. ‘The Motorola Codex 3260FAST modems have a tendency to renegotiate the speed periodically which can cause a RULA disconnect. By limiting the speed to the above stated maximums, more reliable RULA connections have been experienced during Honeywell connections to other sites. To change the maximum speed of the modem, tab down to MODULATION OPTS and then over (right arrow button) to MAX RATE. Set the max speed to 19.2 Kbps by pressing the down arrow until 19.2 shows on the LCD display and then press the Enter button. Then call the TAC modem again. Also, make sure that the 15-pin AUI cable to the DaynaPORT connector is firmly seated and locked to the socket. Continued on next page Honeywell Industrial Automation and ControlTAB __PD 17 A01 (A) PAGE _16 DATE _2 DEC 1996 TAClink Manual, Continued Block Diagram See Figure 9 on page 17. If the software is configured and loaded correctly, and all connectors, cables, tees, terminators, transceivers, bridge and modem seem to be working OK, and no diagnostic or normal communications can be established with TAC, it is possible that there is a bad piece of hardware in the user's system. If the user has spare Ethemet cables, transceivers, tees, and terminators, the time to replace them would be now. If problems still persist, troubleshooting the DaynaPORT would be next. The power connector can be removed and reseated to make sure all of its LED's light up momentarily. The power LED is not suppose to be lit all the time, only when the DaynaPORT is active in a RULA session or when power is reestablished to the DaynaPORT. Step A in Figure 9 shows the two new SCSI cables added for RULA. A new ribbon cable replaces the existing one that connected between the I/O card and the cartridge drives. It has one additional connector for the new SCSI adapter cable that connects from this cable to the DaynaPORT. If RULA diagnostics or normal connections still don’t work, and the user has more than one DaynaPORT available, establishing a DaynaPORT to DaynaPORT connection in the same room would be the next step (Step B in Figure 9 - use the BNC connector on the DaynaPORTs). TAC may also have a spare DaynaPORT and a RULA mounting kit that can be shipped for test purposes for a short time to the user's site. Step C would be to connect an Ethemet cable directly between the MAUs that are connected to the DaynaPORTS. If everything checks out to this point, then Step D would be to checkout the bridges (Xyplex has a bridge-to- bridge loopback test explained in the RULA User's Manual, Section 1.12). The last item to check out would be the modems (Step E), where a temporary replacement with a spare from TAC (if available) may help. Check that the correct cable has been installed at Step D. It is normally a 25 pin cable wired one for one. Xyplex does furnish a cable to connect between the bridge and modem. See Appendix A for its part number. Step E is the phone line. You should be able to dial up one modem from the other modem independent of the rest of the system. See PD 17 BO1 (A) for setups if you are using the Motorola Codex 3260 modem. It may be necessary to put in a Data Line Analyzer to troubleshoot further. This additional help can be provided by Honeywell Network Service through your Honeywell Sales representative. ‘Continued on next page oneyweli Industrial Autonation and ControlTAB PD 17 AO1 (A) PAGE _17 DATE 2 DEC 1996 TAClink Manual, Continued Block Diagram, Typical system interconnections. Continued HOST a es! —— cables aul erent Univeral | 6 Cable Cable Bridger |Saton |, FE DaymePORT EAU MAU) Rotor Ut | > 2 3 o DaynaPORT Modem REMOTE Figure 9 - Hardware Troubleshooting Table 2 RULA Cables Description Part Number ‘SCSI ribbon cable from VO | 51304871-100 card to cartridge drives. ‘SCSI round cable from 51304875-100 ribbon cable to DaynaPORT B | AUIcable from DaynaPORT | 51308138-100 @___|toMAU ‘MAU units 51191782-100 Furnished by customer Cc Ethernet cable, 2-tees, &50 | Furnished by customer ohm terminators. 25 pin cable Xyplex = MX-151-3074 Telephone line Furnished by customer © Included in the RULA hardware mounting kit. ‘Continued on next pageTAB __PD 17 A01 (A) PAGE _18 DATE _2 DEC 1996 TAClink Manual, Continued 6. Appendix A ‘Addresses and/or telephone numbers of third party companies: Xyplex, inc. (for 3401 bridges) 330 Codman Hill Road ‘Mode! N3-3401-002700 Boxborough, MA 01719-1708 Part # 500-8074CB Tel.: 508/264-9900, FAX: 508/264-9930 Contact TAC for Cont. disk ‘Cable from Xyplex to Modem: MX-151-3074 Cisco Systems, Inc. (for 2501 bridges & 10.3 sw) P.O. Box 3075 1525 O'Brien Drive Menlo Park, CA 94026 Tel.: 416/826-1941, FAX: 415/326-1989 Motorola World Headquarters (for Codex 3260F AST V.34 S/A modem 20 Cabot Boulevard Part Number: 42600) Mansfield, MS 02048-1193 Tel.: 508/261-4000, FAX: 508/337-8004 AT&T Paradyne (for Comsphere 3830 modems) 8550 Ulmerton Largo, FL 34641 Tel.: 819/530-2268 Dayna Communications, Inc. (DaynaPORT model DPO802H for 120v ‘Sorenson Research Park ‘or model DPO802HS for 220v) 849 W. Levoy Drive Salt Lake City, UT 84123-2544 Tel.: 801/269-7200, FAX: 801/269-7363 Allied Telesis. (transceiver description: CenterCOM AT-MX10,10BASE2 forthin coax cable) —__ Honeywell part #51191782-100 Tel: 415/964-2771, FAX: 415/964-0944 Phoenix TAC: Tel.: 602/313-5558, FAX: 602/313-5476, RULA Modem Tel.: 602/313-5131 DaynaPORTs Ethernet addresses: 008019100812, 0080191008, (00801910DCA6 Continued on newt page Honeywell Industrial Astonation and ControlTAB PD 17A01 (A) PAGE _19 DATE _2 DEC 1996 TAClink Manual, Continued 7. Appendix B Bill of materials (per site) is as follows when using RULA over standard telephone lines. Table 3 Bill of materials [Hem Touant [an Number] MP-RLSWO1 _| RULA software and license (this includes RULA Manuals MP- RLSWO, RULA User's Manual and RLO3-400, Specification and Technical Data Manual) BO {7 MP-RLK Tx RULA hardware mounting kit with instructions (xx depends on console type). See Table 4 co [2 51191782-100__ | MAU Ethernet transceivers De |i DPO802H 120volt Dayna Converter DPO802HS 240volt Dayna Converter EO |7 'N3-3401-002700 | Xyplex bridge, model number 500-8074CB__| Part number FO MX-151-3074 | Xyplex bridge 25-pin straight cable from Xyplex to the modem Golt 42600 Motorola modem (specify Codex 3260FAST V.34 S/A) H@ |asreq | None Thin Ethernet cable between MAUs (10 feet or longer), 2- : Tee's and 2- 50 ohm terminators © [7 None Xyplex bridge software floppy, get from TAC after Xyplex arrives oO ® @ ® © ® order from: Honeywell Regional Sales order from: Dayna Communications, Salt Lake City, UT, telephone: 801/269-7200 order from: Xyplex, Inc., Boxborough, MA, telephone: 508/264-9900 order from: Motorola World Headquarters, Mansfield, MA, telephone: 508/261-4000 order from: purchase locally order from: Honeywell local TAC (after Xyplex arrives at the site), telephone in USA: 800-822-7673, in Canada: 800-263-4000, and in Europe: (32-2)728-2657 [aes 4 RULA Mounting Kits a MP sel RULA Classic Console (older furniture) Hardware Mounting MP-RLKT11. Kit Installation. MP-RLKTO2 RULA Micro TDC 3000 Hardware Mounting Kit installation. - MP-RLKT12 MP-RLKTOS RULA X3000 Console Hardware Mounting Kit Installation (for Ergonomic (Z) US or UxS) [MP-RLKTO4 |" NO_| RULA Universal Work Station (UWS) Hardware Mounting (MP-RLKTI4_[ YES | Kit Installation. © CEs for European CompliantTDC 3000 TAB PD17 CUSTOMER PAGE Bot (A) RESOURCE MANUAL DATE 15 DEC 1995 MOTOROLA CODEX 3260FAST V.34 MODEM SET UP PARAMETERS TO USE FOR RULA Background In order to establish a modem link using the Codex modems, certain items and parameters should be checked on a new modem. Action To start with, after the power has been tumed on for the bridge (Xyplex or Cisco) and the modem, and the cable to the modem from the bridge has been connected, the following LEDs on the modem + should be on: RD, TR, TD and CD. After a modem link has been established, these five (5) LEDs should be on: RD, TR, RVOH, TD, and CD. The left most LEDs, RD and TD, should blink fast. If thi not the case, please check to see if the modem cable from the bridge is the one that's suppose to be there (a 25-pin straight through cable, which can either be purchased from Xyplex: MX-151-3074, or from Cisco: 72-0793-01). You also need to look under the ACU OPTS to. see if ACU Select = V25b (see below). To change parameters in the modem: + Press the Retum key to get to the beginning (Disconnect T/D?). ¢ To get to the options (Modulation, ACU, etc.), press the Down button. + To get to the different parameters under each option, press the Across (side) arrow. + To change a parameter, press the Down arrow and the press the Enter button. + After entering all your changes, under the Disconnect T/D? option (press Retum twice), + Ifyou move Across to Save Changes = 1 and press Enter. It should indicate that your changes have been saved so if you power the modem off and on, you will have the same information as before. The following are all the entries that TAC has found to work with the modem. Some parameters are essential (for example, ACU Select = \V25b, Answer = Ring #1, V.34 Asym = On) while the values of other parameters can vary. However, we suggest you look at them all and change where appropriate. Continued on next pageTAB __PD 17B01 (A) PAGE _2 DATE _15 DEC 1995 SET UP PARAMETERS, Continued DISCONNECT T/D? FX = 200 Tx = 200 [MENU | PARAMETER PARAMETER INSTRUCTIONS _ ‘where 200 = doesn't matter if there's a value there or not DTE = 9.6 COMMND Phaselitter = Odg ‘Select Options = 1 ‘Save Changes = 1 Power Up In= 1 Reinit Menory?, Don't press Enter on this one, press Across (side) arrow Dial From = ‘where x is 1-9, where the telephone number you wantto dial is stored ‘where x is 1-9, see example above ‘where xis 1-9, see example above Link Phone# = x ‘where xis 1-9, see example above Enter then Dial “To enter a temporary phone number. ‘Auto Redial = Off 'S-Reg 000 = 000 TEST OPTS TEST = End Test ‘Accept ADL = On. LAL Busy Out = Off MODULATION OPT'S RESTORAL OPT'S Line = Dial Mod = V.34 Auto, ‘Auto Type = CCITT Low Speed = Bell Max Rate = 26.4 Recommended maximum rate so RULA is not interrupted Min Rate = 300 V.34 Asym = On Very Important! Fast Call = Off ‘AdaptiveRate = On Mode = Originate Clock = Intemal Retrain = High BER Longspace = Off PSTN = On ‘Guard Tone = Off, Restore = Off ECIDC OPT'S. Mode = Auto Rel Buffers = Regular ‘Continued on nextpage Woneyeeli Tndustrial Astonation and Contra?TAB __PD 17 B01 (A) PAGE _3. DATE 15 DEC 1995 SET UP PARAMETERS, Continued "ACU OPT'S PARAMETER ACU Select = V25b Very Important! ‘AT Form = Asyne \V25Form = Bitsyne NoAGU Form = Async Default Dial = Off ‘Answer = Ring #1 Very Important! ‘Asyne Echo = On ‘Char Length = 10 V25 Char = ASCII ‘Syne Idle = Char \25Resp = V25bis Parity ‘AT Msg = Before CD. AsitCode = Enable AisitForm = Verbose ‘Con Msg = DTE Rate, Rel Msg = Off, LPDA2 Addi LPDA2 Det ‘Call Progress = x ‘where x can be 1-4 TERMINAL OPT'S DTE Rate = Auto Flow = XON/XOFF. ‘Speed Conver = On RemRTS/DCD = DCD Loss Dis = S10 DSR = High ‘Overspeed = 1%, DTA Delay = S25 DTE Ct 140 = Off DTE Ct 141 = Off DTE pin 25 = Test Continued on next page Roneywell Industria} Automation and ConteolTAB __PD 17801 (A) PAGE _4 DATE _15 DEC 1995 SET UP PARAMETERS, Continued _ PARAMETER INSTRUCTIONS TELCO OPTS Telco = RIC LL TX Level = 0 Line Compen = Off ‘Speaker = Dialing DIALING OPT'S Call Timeout = 60 Blind Dial = S6 Pulse Cycle = 40% Tone Length Enter Password? No entry required Password = Disable ‘Set Protection? No entry required ‘Change Password? | No entry required ‘ACCESS SECURITY | PW Verify = Dis Callback = Off imt Num Aged — Off Enter Group PW? No entry required Group PW = Disable Tone = None ‘Sim Ring = Disable DialRstret = Off NETWK GNTL OPT'S | OverrideMode = Off NC Address = 000 NC Port Rate = 75 Pass Thru = Opt t RMT CONFIG OPT'S | Init Rt Cnfg? No entry required RmtAce = Enable ‘SETRMTLL ADDR | New Address = 000 ‘Rimt Serf = 000000000 imtNest Modem = No “Enter to Set ‘SRCH RMT LL ADDR | Amt Ser# = 000000000 mtNest Modem = No “Enter to SearchTDC 3000 TAB PD 18 CUSTOMER PAGE INDEX 1 RESOURCE MANUAL DATE 23 JUN 1996 18. HONEYWELL 620 LOGIC CONTROLLER SYSTEM (LCS) A o1. 05, 14, 15. 16. 7. 18. H620-10/11/14/15/16/20/25/30/35 PROCESSORS, Processor Rack ‘A. 620-1690, -1693, & -3691 processor racks Processor Module (PM) 620-25/35 Processors 620-25/35 Processors IPC 620-25/35 Processor Module (620-0080) 620-0080 Proc Mod 620-25/35 V.R 2.4 to 2.5 620-11/14/16 Processor FW V.R 1.6 620-11/14/16 Compatibility with CIM's & DCM's 620-11/14/16 Firmware Error V.R 1.6 620-25/95 & LM 620-0080 FW V.R2.6 620-1181/1431/1631 Firmware V.R 1.8 620-1200/1633/3632 processor FW upgd V3.1 620-35 LCS/Logic Manager Extended Diagnostics Processor Firmware Upgrade V.R 3.2 620-0080 Processor Module with V.R 3.0 Firmmware Erroneous Clearing of Outputs Supply Module (PSM) 620-0036 and 627-7037 Power Supplies 620-0036 Power Supply Loading 620-0036 Power Supplies 620-0046 PS in 620-11/14/16 systems 620-0047 24 Vc PS possible erratic oulpul jedundaney Control Module (RCM) - option 620 Redundanoy/Serial VO 620-0059 Redundancy Control Module Redundancy Control Module 620-0059 Upgrade 620 Redundant Processors Redundancy Control Module/Augmented Run Programming 620-0059 Redundancy Control Module Using Parallel VO in Redundant IPC 620 Configuration Redundancy Control Module (RCM) Compatibility 6620-0059 Redundancy Cont. Mod. FW V.R 2.2 tvay Interface Module (HIM) - option 620-0081 Hiway Interface Module Rel 1.3 620-0081 HIM Applications with Hiway Coupler Module 620-0081 Hiway Interface Module - Firmware Release 2.0, 620-0081 HIM V.R 2.1 620-0081 HIM V.R 2.2 LCS 620 Hiway Interface Module V.R 2.3 Data Collection Module (DCM) - option ‘A. 620-0048 Data Collection Module Logic Manager Module (LMM) - option ‘A. Logic Manager Upgrade to Release 301 B. Suggested Switch Settings for LM installations Loop Processor Module (LPM) - option ‘A. 620-0072 LPM / series 9000 invalid Data Reads ZECPAS"zrommoOm> i in serial VO systems ZOMMIOB>Bmoow> mmpoppE- Continued on next pageTAB PD 18 Index PAGE _3 DATE __1 JUL 1995 18. HONEYWELL 620 LOGIC CONTROLLER SYSTEM (LCS), Continued B. H621 UNIVERSAL INPUT/OUTPUT SYSTEM, Continued 18. Pulse Input Module (PIM) ‘A. 621-0008 Pulse Input Module Incorrect Accumulator 18. Resistance Temperature Detector Module (RTDM) ‘A. 621-0025R RTD Module Scan Rate Shutdown Problem 20. Controller Access Module (CAM) ‘A. 621-0016/R Controler Access Module Data Read Problem 99. General ‘A. Erratic Operation of Outputs B. DC digit input circuit drawings C. H623-50 LOADER/TERMINAL 10. Software Tapes ‘A. Ladder Logic Tape Problems in Ver.3.X of the MS-DOS Loader 99, General A. 623-51 Loader/Terminal B. 623-51 Loader C. 623-51 Memory Changes/Force Function D. 627-70 COMMUNICATIONS AND OPERATIONS PROCESSOR (COP) 01. COP Processor Rack ‘A. MiniCOP Serial Port #3 Failure 07. Language Independant Processor (LIP) ‘A. 627-7036 Language Independent Processor FN#72. B. 627-7036 Language Independent Processor FN#86 99. General ‘A. MiniCOP Firmware Problems E. 623-60 MS-DOS LOADER 01. PC Interface Hardware ‘A. 623-6010 & 623-6020 to IBM PS/2 Compatibility B. Extemal Power Supply for RS-232 to 422 Converter 02. Software File Transfer Limitations in the IPC 623-6000 {623-6000 Documentation Corrections 623-60 MS-DOS Loader Ver. 2.0 Software Problems MS-DOS Loader Software Problem 623-60 MS-DOS Loader Version 2.X Upgrade Kit 623-60 MS-DOS Loader V.R 3.2 Discrepancies MS-DOS Loader V.R 3.4 623-60 MS-DOS Loader Version 4.X Upgrade Kit MS-DOS Loader V.R 42 MS-DOS Loader V.R 4.3 Procedure For Converting A 620-96 Ladder Program To A 620-35 Z. UNCATEGORIZED 620 LCS 01. LCS Field Notice Summary ‘A. Honeywell 620 LCS Field Notice Summary 02, LCS Field Upgrade Kit Summary ‘A. Support Controller Upgrade Kits 99, General ‘A. RS422/RS485 Multi-Drop Networks B. _Version/Revision (V.R) Definition AEP TOMmoom> Honeywell Industrial Automation and ContzotTDC 3000 ‘TAB PD 18 CUSTOMER PAGE __AQ] (A RESOURCE MANUAL DATE __7-17-92 FB: 18 FB date: 6-1-92 620-1690, 620-1693 AND 620-3691 PROCESSOR RACKS. Background Action The 620-1690 and 620-1693 processor racks support a total of eight local 1/O modules or up to seven I/O modules and one Serial Link Module. The 620-3691 processor rack supports a total of six /O modules or up to four /O modules and two Serial Link Modules. Only the right-most I/O card slot (slot H) in the 620-16 racks andthe two right-most I/O slots (slots E & F) in the 620-36 rack are designed to ‘support Serial Link Modules and/or I/O modules. Honeywell's Installation and Processor Users manuals do not mention that certain specialty modules will not physically install into the right- most I/O slot(s) because the upper backplane connector is offset to. accept only the Serial Link Module. All 621-I/O modules with the exception of those listed below will install into the right-most /O slot(s) of these racks. 621-0012 ASCII Communications Module 621-0016 Controller Access Module 622-1030 Servo Axis Module 622-1040 Servo Control Module 622-1041 Independent Multi-Axis (IMA) Servo Control Module 622-1042 Point-To-Point (PTP) Servo Control Module 624-7002 DMCS Gateway 500 Module (installs into 620-1690 racks only) 627-100X Minicop Modules Moneywell Industrial Autonation end ContrastTDC 3000 TAB PD 18 CUSTOMER PAGE __AOS (A) RESOURCE MANUAL DATE ___6-2-88 Field Notice 71 Issued 2-24-88 ‘ITEM: 620-25/35 PROCESSORS [PTOM: The program memory checksum routine in 620-0080 processor modules, that was to be corrected in firmware Revision 48 or greater, still does not work correctly. Processors with Revision 48 or 49 firmware (V.R 2.0 or 2.1) will detect a checksum error after a cold start (power off, no battery), but will not detect a subsequent checksum error. ADVICE: Firmware Revision 50 will perform the checksum routine correctly, It is recommended that all 620-0080 processors not at this revision level be upgraded to Revision 50 (V.R 2.2) by ordering the 620-0080 upgrade kit: M/N 220-0007. Honeywell Industrial Automation Systems Division Noneywell Industrial Services DivisionTDC 3000 TAB_PD 1s CUSTOMER PAGE AOS (B) RESOURCE MANUAL DATE 11-21-88 Field Notice 90 Issue Date 9-16-88 ITEM: 620-25/35 Processors BACKGROUND: A new firmware revision for the 620-0080 processor ACTION: is available to correct a possible condition whereby the processor will not power-up correctly when the keyswitch is in the run, run/program, or disable position. If a system experiences this condition, the processor will remain in the software program mode after power is restored to the system. To recover, the processor must be powered-up while the keyswitch is in the program mode. Firmware Revision 2.3 (displayed as firmware code 51 on a 623 L/T) will correct this situation. It is recommended that all 620-0080 processors be upgraded to Revision 2.3 by ordering the 620-0007 upgrade kit: M/N 220-0007. Honeywell Industrial Automation Systems Division Honeywell Industrial Services DivisionTAB _PD 18 AOS (C) PAGE _2_ DATE _8-16-89 _ PROBLEM NO. 2 This particular bug is only noticeable in Serial 1/0 configurations that have the 621-0004 System Diagnostic Module (SDM) installed. In revision 51, ag a result of a PRGM to RUN mode change or a processor power cycle, the PLC processor will go through a complete Memory Word Zero diagnostic routine. While in this routine, the CLEAR OUT signal is held high for a 600 millisecond period of time.’ This length of time is long enough to cause SLM outstrobes to be enabled to SIOMs on the link. This will cause the ‘scan LED’ on any SDM in the link to momentarily blink, since after this 600 millisecond period the SIM outstrobe signal is once again disabled due to the CLEAR OUT signal changing back to a low state. It will remain in the low state until the PLC processor is scanning the control program. EX Revision 52 corrects this ‘nuisance bug’ by reducing the amount of tine within the diagnostic routine that the CLEAR OUT signal is held high, to a point that the SLM does not have the opportunity to enable its outstrobes ENHANC: The current checksum calculation routine in the system per run time scan has been considered too slow. Consequently, it has been rewritten such that the time required to calculate Process Memory Module checksum has been decreased by a factor of two (2). In revision 51 the checksum routine read six (6) memory words per scan. Now, in revision 52 the loop reads twelve (12) menory words per run time scan. The formula shown below can be used to determine how often a new checksum is calculated by the PLC processor. Kmem/12*Tscan=CTnew where: Kmem = Size of user's program. Tscan = PLC scan time. CTnew = Frequency of nevly calculated checksum. UPGRADE KIT INFORMATION Upgrade kit NO. 220-0007, V.R 2.4 contains these changes for the 620-0080 Processor Module. The upgrade kit will be available at no charge for 90 days, starting August 1, 1989. After November 1, 1989, the upgrade kit will have a list price of $100.00. Any 620-0080 Processor Modules shipped after July 1, 1989, will be shipped as V.R 2.4 and will incorporate these changes and are not effected by this Field Notice. Automat ion systens Division Honeywell Industrial Services CenterTDC 3000 TAB PD Je CUSTOMER PAGE ___AO5 (C) RESOURCE MANUAL DATE 8-16-89 Field Notice 108 Issued 6-21-89 ITEM: IPC 620-25/35 PROCESSOR MODULE (620-0080) REVISION CHANGES FROM 51 TO 52 - REVISION 52 V.R = 2.4 BACKG! This Field Notice describes two bugs along with their fixes and one enhancement that have been made to the 620-25/35 620-0080 Processor Module revision 51. The revision level information of the processor is displayed on the 623-50/51/60 Program Title Screen. PROBLEM NO. 1 In revision 51 a problem exists when the scan loss timer is disabled and an illegal opcode is detected in the user program during normal program execution before a new checksum is calculated. This could be caused via the CIM writing an invalid opcode for that processor into user memory. When the illegal opcode is detected, the processor will stop scanning completely, the settings of the Clear/Freeze dipswitches will be ignored and outputs will remain in their last state. If the scan loss timer is enabled, the settings of the Clear/Freeze dipswitch will be read upon ‘time out of the scan loss timer and outputs wil be set accordingly. FIX This situation is corrected in revision 52. When an illegal opcode is detected, processor execution is immediately directed to the Set Software Program mode routine, independent of the scan loss timers use. This causes the Clear/Freeze dipswitches to be read and outputs to be set accordingly. In both revisions (51 and 52), the corrective procedure is to reload program memory. Moneywel Industri ‘Automation systens Division Honeywell Industrial Services CenterTDC 3000 TAB PD 18 CUSTOMER PAGE AO5 _(D) RESOURCE MANUAL DATE 9-25-90, FIELD NOTICE #122 Issued 2-1-90 ITEM: 620-0080 PROCESSOR MOD. 620-25/35 REV. CHANGES FROM 2.4 to 2.5 BACKGROUND: There is a bug in the compare matrix instruction that causes a situation where only a few of the mis- compared addresses will print. The problem occurs when Matrix "A" addresses are in the bit I/O area and Matrix "B" is in the register address area. ACTION: Upgrade Kit 220-0007 can be used to resolve this condition or another solution is possible by application program. The user could copy the Matrix "BY into the bit I/O area and then compare Matrix "A" to the new Matrix "B" addresses. UPGRADE KIT INFORMATION: Upgrade Kit 220-0007, V.R 2.5, contains the change to correct the above noted problem. Customers wishing to upgrade should contact Customer Service in York (717) 771-8111. The upgrade kit has a list price of $100.00. Honeywel Industrial Automat on and Control DivisionTAB _PD 18 AOS (E) PAGE _2 DATE _9-28-S0 3. REMOVAL OF LOADER CABLE COULD CAUSE SCAN LOSS In all previous versions of the 620-11/14/16, if the processor was running and connected to a loader, and the loader was monitoring a line of logic in the program; it was possible for the removal of the loader cable to cause the processor to enter a Scan Loss condition. The problem would occur if the cable was removed during the PLC scan, after the loader had requested monitor information about a line, and before that line was executed in the PLC scan. For this reason, the problem was more likely to occur if a number of option cards were present in the system (since they are serviced after the loader port, but before the user program scan starts), or if the line being monitored was near the end of the ladder logic program. The program, which was caused by an error in the loader port service routine, has been corrected in V.R 1.6 of 620-11/14/16 firmware. UPGRADE KIT INFORMATION All of the problems described above have been corrected in V.R 1.6 of the 620-11/14/16 firmware. Users who wish to upgrade their processors can do so by ordering Upgrade Kit 220-0015 for 620-1131 Processors, Upgrade Kit 220-0016 for 620-1431 Processors, or Upgrade Kit 220-0017 for 620-1631 Processors. These upgrade kits, which will be available May 10, 1990 will be offered at no charge for a period of 90 days. Customers wishing to upgrade should contact Customer Service in York (717) 771-8111 with a no-charge purchase order number, and the required quantities of upgrade kits. After August 10, 1990, the kits will have a list price of $100 each. Honeywell Industrial Automation and Control DivisionTDC 3000 TAB PD 18 CUSTOMER . PAGE AOS (E: RESOURCE MANUAL DATE 8-90 FIELD NOTICE: #128 Issued 5-10-90 ITEM: © 620-11/14/16 Processor Firmware V.R 1.6 Three problems have been discovered in V.R 1.5 of the 620-1131, 620-1431, and 620-1631 Processor Modules. These problems, detailed below, have been corrected by changes implemented in V.R 1.6 of the 620-11/14/16's firmware. The purpose of this Field Notice is to inform you of the problems discovered, and to provide instructions for ordering the upgrade kit which corrects the problems. CARD FAULT ADDRESSES REPORTED ARE INCORRECT A timing problem in V.R 1.5 of the firmware caused the processor to incorrectly identify the address of a card which is reporting a fault condition. The card fault addresses reported by V.R 1.5 of the 620-11/14/16, were 8 addresses too high. These can be viewed through the Diagnostics function of the Auxiliary menu of the loader or by examining system Status Registers 2416 through 2431. A firmware change implemented in V.R 1.6 corrects this problem. It should be noted that this problem existed in V.R 1.5 ONLY, and that the Card Fault Count reported by the system in V.R 1.5 is correct. CORRUPTION OF PULL DATA DURING KEYSWITCH TRANSITIONS In earlier revisions of the 620-11/14/16, it was possible for data to be PULLed from the wrong address when the keyswitch of the 620-11/14/16 was being turned between RUN/PROG and DISABLE. This problem was caused by an error in logic which would not allow correct addresses to be recognized by PUSH/PULL cards during keyswitch transitions. The error, which existed in V.R 1.5 and earlier revisions of the 620- 11/14/16, has been corrected in V.R 1.6. Moneywell Industrial Autonstion and Control Division[Teas _pp 18 a05_(F) PAGE 2 DATE _11-14-90 It should also be noted that, since Flag Mode of operation uses addresses 2032- 2047 as the Flag Bit addresses in 620-20/25/30/35 processors, and since the 621-9938/9939/9940 32-Pt. Serial 1/0 System uses addresses 2040-2047 for status information, 32-Pt. Serial 1/0 and Flag Mode DCM operation CANNOT be used together in the same 620-20/25/30/35 system. Attempts to combine the two will result in flag messages being sent whenever the 621-9939 Serial Link Module toggles a status bit. As the Flag Bit addresses are software configurable in the 620-16 series processors, Flag Mode DCM operation CAN be used with the 32- Pt. Serial 1/0 System in 620-11/14/16/36 systems IF the Flag Bit addresses are NOT set to overlap addresses 2040-2047. Finally, Flag Mode DOM operation is NOT fully compatible with the Logic Manager system, because the IM is a 620-35- based system that either uses 32-Pt. Serial 1/0, or requires the user to set address 2045 to indicate that 1/0 is active when parallel 1/0 is used. In either case, flag messages will be sent when bits are set by the system. Because the 620-0043 GIMs DOES NOT support flag mode, these modules were not affected by these problens. Upgrade Recommendations: Due to the intermittent nature of these problems, users of CIMs and DCMs’in 620-11/14/16 processors, and users who employ the Flag Mode in the DCMs, should check the firmware revision of their modules and determine if they are at an acceptable revision level. The minimum acceptable revision levels are summarized below. There is no need to update units which are not used in 620- 11/14/16 systems and which do not use Flag Mode. ‘Option Module | Upgrade Kit | 620-11/14/16 | Flag Mode 20-0043 CIM | 220-0002 VeR 1.2 620-0044 CIM | 220-0044-2 | not yet avail 620-0048 DCM | 220-0048-3 Customers wishing to upgrade may do so by ordering the appropriate Upgrade Kit. To order upgrade kits, contact Customer Service in York at (717)771-8111. Please be prepared to provide a purchase order number when the order is placed. oneyeell Industrial automation and Control DivisionTDC 3000 TAB PDs CUSTOMER PAGE ___AOS (F RESOURCE MANUAL DATE 11-14-90 FIELD NOTICE: #134 Issued ¢-19-90 7" i 620-11/14/16 Compatibility with CIM's & DCM's SUBJECT: 620-0043 Computer Interface Module (MODBUS) V.R 1.1 620-0048 Data Collection Module V.R 3.1 620-0052 Dual Port DCM V.R 2.0 This Field Notice is intended to provide users with guidelines for what CIM and DCM module revisions are compatible with the 620-11/14/16 processors, to describe an additional change to Flag Mode of Operation which was incorporated into the 620-0048 and -0052 DCM modules, and to describe several system incompatibilities with Flag Mode of Operation. 620-11/14/16 Compatibilit: A problem with option module communications was detected during preproduction testing of the 620-11/14/16 processors. The problem was caused by the fact that the 68000 processor on the 620-16 and the 6809 processor on the CIM/DCM modules run on two separate clocks with different frequencies. Due to the different frequencies, it was possible for certain control signals to experience a glitch, causing the CIM to occasionally read inaccurate data from the PLC. This problem has been corrected by a firmware change which filters out the glitch. The firmware change has been incorporated into V.R 1.1 of the 620-0043, V.R 3.0 of the 620-0048, and V.R 2.0 of the 620-0052. Because of the change, these and higher revisions of these modules ARE compatible with the 620-11/14/16 processors. LOWER REVISIONS should NOT be used with the 620-16 series processors because intermittent problems with inaccurate data could occur. Furthermore, it should be noted that the current revision of the 620-0044 DMCS CIM (V.R 1.3) is NOT compatible with the 620-11/14/16 processors. This compatibility will be available in V.R 2.0 of the 620-0044. A separate Field Notice will be distributed to announce the availability of this revision when it is released. Flag Mode Problem in 620-0048 and 620-0052: A problem was discovered in the Flag Mode of operation of the 620-0048 and 620- 0052 DCMs. In earlier versions of the firmware for these modules, it was not always possible to guarantee that a transition of a flag bit would be detected. Missed flag bits would occur randomly, a very small percentage of the time, in certain system configurations. Changes made in V.R 3.1 of the 620-0048 and in V.R 2.0 of the 620-0052 ensure that ALL flag bit transitions are detected by the CIMs ‘The problem was never present in the 620-0044 CIM. Honeywell Industrial autenation and Control DivisionTDC 3000 TAB __PD 18 CUSTOMER PAGE AO5 (G) RESOURCE MANUAL DATE 1-28-91 Field Notice 138 Issued 12-28-90 ITEM 620-11/14/16 Firmware Error V.R 1.6 PROBLEM: Multiple errors have been discovered in Version 1.6 and earlier releases of the 620-11/14 and 16 controller firmware. It is recommended that all users upgrade to V.R 1.7 to alleviate these problems. 1. Should a processor scan loss occur during an option modules window, the window would not close properly causing the system diagnostics to detect a backplane failure. Presently the user would be required to cycle power to recover from this fault. 2. Disconnecting the data cable from the fixed communications port on the 620-11/14/16 could result in the transmitter being left enabled which will lock up a multi-drop configuration. 3. A .01 second resolution (TOF) timer energizes its output upon power up in the run mode or upon a program to run mode transition even though the preceding logic is false. The output of the timer remains energized for the duration of the preset value. 4, If a 623-60/61 loader is connected to the processor while a program containing a sequencer is being downloaded into memory via a CIM, the Processor may go into an erratic scan. Presently there is no diagnostic to detect this situation. 5. A compatibility problem exists between the 620-11/14 and 16 fixed communications port and the Honeywell PLC gateway (PLCG). The fixed port receiver is turned off when the transmitter is active and is held off for four character times after the transmission is complete. The PLC3, however, begins to transmit to the fixed port 3.5 character times after receiving data from the fixed port. This causes the comm port to miss portions of the message and return an error message to the PLCC. Upgrade Kit Information: Kits may be ordered by contacting our Order Entry Department at 717-771-8111 and requesting the respective upgrade kits for the processor model numbers listed below. Please be prepared to provide the serial numbers of ycur processors: MODEL # Pe (ODE! 620-1131 220-0015 620-1431 220-0016 620-1631 220-0017 Honeywell Industrial Automation ond ControlTOC 3000 TAB PD 18 CUSTOMER PAGE AOS _(H RESOURCE MANUAL DATE 5: m SUBJECT: 620-25/35 & LM Processor Module 620-0080 FW V.R. 2.6 PROBLEM DESCRIPTION: A problen has been noted with the Cold-Start feature of the 620-25/35 Logic Controller firmware. The firmvare, which is also used in Logic Manager systems, has a feature which allows the processor to detect if the unit lost battery backup when it was powered down. The loss of battery backup when the processor is powered down can result in the corruption of user program memory and/or register table data, In order to prevent the processor from running with a corrupted program, the processor clears the program memory on power-up when this condition; known as cold-start, is detected. All field-released versions of the 620-25/35 firmware have this feature which clears user program memory during a cold-start; however, a problem existed in the way the register table data was cleared in versions before V.R 2.6. The software routine which was supposed to clear the registers used @ scratch RAM location to know how many registers it was supposed to clear; however, in versions betore V.R 2.6, this RAM location was not properly initialized. For this reason, the routine did not always properly clear all of the register table data. V.R 2.6 of the 620-0080 Processor Module corrects this problem by ensuring that the proper number of registers are alwzys cleared during a cold-start procedure. Please note that register table data is normally maintained through a power-down; it is the loss of the battery backup while powered down that forces the processor to cold- start UPGRADE KIT INFORMATION: V.R 2.6 firmware can be obtained by ordering model number 220-0007, 620- 0080 Processor Module Upgrade Kit. This upgrade kit, which is currently available in stock, will be offered at no charge until July 31, 1991, at which time the normal list price of $100 per kit will apply. To order the kit, please contact Customer Order Entry in York at (717) 771-8111 Please be prepared to provide a no-charge purchase order number when calling to order free upgrade kits. Honeywell Industrial Automation end ControlTOC 3000 TAB PD le CUSTOMER PAGE AOS (1 RESOURCE MANUAL DATE 1 SUBJECT: 620-1131/1431/1631 Processor Firmware Rev. 1.8 PROBLEM: An error has recently been discovered in versions of 620- 11/14/16 processors firmware previous to V.R 1.8. A push operation following a floating point comparison will not display the proper result. The floating point comparison routines do not reset the stack’s push pointer after the comparison operation, hence a push following the comparison line will include the first floating point data element as well as any other data on the stack. UPGRADE KIT INFORMATIO! Firmware upgrade kits may be obtained free of charge until July 31, 1991, after that date the charge will be §100 per upgrade kit. ‘Kits may be ordered by contacting our order Entry Department at 717-771-8111 and requesting the respective upgrade kits for the processor model numbers. listed belo’ MODEL ¢ UPGRADE KIT MODEL # 620-1131 220-0015 620-1431 220-0016 620-1631 220-0017 Please be prepared to provide the serial numbers of your processors and a no-charge purchase order number at the time of your call. Honeywell Industrial Autonat ion and ControlTDC 3000 TAB PD 18 CUSTOMER PAGE __AQS (J RESOURCE MANUAL DATE __7-9-92 FN: 147 FN date: 6-1-92 620-1200/1633/3632 PROCESSOR FIRMWARE UPGRADE - VERSION 3.1 Background Bug Fixes Upgrade Kit The Version 3.1 processor firmware upgrade adds mutti-drop functionality to the Loader port of the 620-1200/1633/and 3632, processors. This firmware will allow a nodal address to be programmed into the individual 620 processor. One 623-60 loader package (version 4.1 or greater) will then be able to interface any of up to 31 processors on the network by simply requesting its nodal address. 1) When an attempt was made to subtract two floating point operands which differed by more than 224 an addition operation would occur. 2) When the user attempted to monitor an invalid step of a sequencer the /O points associated with that sequencer would become corrupted. Firmware upgrade kits may be ordered free of charge until August 15, 1992. After that date the charge will be $100.00 per upgrade kit. Kits may be ordered by contacting Honeywell's Order Entry Department and requesting the respective upgrade kits for the processor model numbers listed below: 620-1200 220-1200-3 620-1633 220-1633-3 620-3632 220-3632-3 Please be prepared to give the serial numbers of your processors and ano charge purchase order number at the time of your call. Woveywell Ioduetriat Automation and contro!TAB __PD 18 A05 () PAGE _2 DATE '_23 DEC 1993 620-35 LCS/LOGIC MANAGER EXTENDED DIAGNOSTICS, Continued 621-9939 (SLM) Expanded Diagnostics Advice 621-9939 Serial Link Module (SLM) V.R 2.3 Expanded Diagnostics Currently, the SLM uses real /O addresses 2040-2047 to post the status of the two SLMs that may reside in a 620-35 or Logic Manager processor rack. ‘These addresses cannot be used for any other purpose. With expanded diagnostics real /O addresses 1992-2039 are also used for diagnostic information when the 620-0080 processor module jumper is set for expanded Serial /O diagnostics; therefore, these registers cannot be used for real /O connections. These additional addresses are used for diagnostic handshake routines between the SLM and the controller. SLM#t 1 diagnostics use addresses 2016-2039; however these addresses may be used for real I/O if SLM# 1 is not used in the system. Likewise, ‘SLM# 2 diagnostics use addresses 1992-2015; however these addresses may be used for real I/O if SLM# 2 is not used in the system. The expanded serial /O diagnostics adds another diagnostic check to the system where actual data is transferred from the Logic Controller's backplane to the SLM and is retumed for verification. This is not user information, but rather itis a test pattem designed for this specific purpose. The test checks for incorrect states on the /O data bus. If auser's system does not have an SLM, or f it has an older SLM which is not updated to V.R 2.3, and the Processor module is configured for ‘expanded serial diagnostics; the Processor will not fail the serial diagnostics. It will simply post specific values into its system status table locations, 3125-3124 for SLM 1 and 3127-3126 for SLM 2, to indicate that an SLM is not present or is present but not tested. Itis not mandatory that users upgrade their systems; however, the extended diagnostics do offer a greater ability to detect system failures and provide ‘an additional level of safety. if the user decides to upgrade and is operating redundant 620-35 LCS/Logic Manager systems, it is mandatory that both systems be upgraded. Additionally, the Serial Link Module diagnostics work in conjunction with the extended processor diagnostics; so, it is necessary to obtain both processor and SLM upgrade kits to take advantage of the ‘extended serial /O diagnostics. Continued on next pageTDC 3000 TAB Po18 CUSTOMER PAGE AOS (K) RESOURCE MANUAL DATE 23 DEC 1993 FB: 22 FB Date: 11-10-93, 620-35 LCS/LOGIC MANAGER EXTENDED DIAGNOSTICS Background The purpose of this Field Bulletin is to announce a product improvement made to the 620-0080 processor module used in the 620-35 LCS and Logic Manager systems and to the 621-9939 Serial Link Module to enhance their tun-time diagnostics. 620-0080 620-0080 V.R 3.0 Expanded Diagnostics: Expanded ‘The 620-0080 Processor Module (PM) expanded diagnostics incorporates Diagnostics: firmware that allows the PM to perform additional checks on the system ‘during the run mode of the processor. The additional diagnostics will add 3- 5 milliseconds to the scan time of the system, but memory word zero (MWZ) time will not exceed 10 milliseconds. ‘One area of expanded diagnostics includes a check of the Register Module (RM) (620-0056) to make sure that simultaneous writes do not occur to the multiple data bases on the RM as a result of a corrupted data table. There was a possibility that a failed decoder chip on the RM could cause multiple outputs to be enabled. ‘A second area of expanded diagnostics includes a check of the System Control Module (SCM) (620-0054) to verify that the contact logic unit on this module is properly decoding programmed single bit relay ladder logic operations. A third area of expanded diagnostics includes additional serial VO diagnostics capabilities described below. This feature is only available if jumper WS (a positionable plug type jumper) is installed on the PM and the Serial Link Module is at V.R 2.3. Additionally, a wire jumper (W3) must be unsoldered and moved to another Position on the PM to recognize the new firmware circuit chips. More details are provided in the instruction sheet accompanying the upgrade kits. 620-0080 \V.R 3.0 Processor modules are not compatible with 620-0055, 2K X 2K Caution Register modules. If this combination of modules is placed in a 620-35 system, the processor will fail expanded diagnostics. Customers with this combination of modules must maintain their 620-0080 Processors at V.R. 2.6 or they must purchase 620-0056, 4K X 4K Register modules if they wish to take advantage of the expanded diagnostics. Continued on next pageTAB PD 148 AOS (K) PAGE 3 DATE _23 DEC 1993 620-35 LCS/LOGIC MANAGER EXTENDED DIAGNOSTICS, Continued Advice, Continued Upgrades With the addition of expanded serial diagnostics, the user must be made aware that shorting the reset contacts (18-19) on a V.R 2.3 SLM will cause the Processor to fail diagnostics and the processor will exit the run mode. In lieu of using the reset contacts, we recommend that the processor be power cycled in the rare instance an SLM need to be reset. SLM modules below V.R 2.3 will shut down the serial links if the module is reset, but the Processor will not exit the run mode. Non-redundant 620-35/ Logic Manager users must realize that when processor diagnostics fail, /O will freeze or clear based on PIOM/SIOM dip switch settings. Redundant 620-35/Logic Manager users must realize that if the lead processor fail diagnostics, the /O control will switch to the available back- up. If there is no valid back-up, the system will react as stated above for a non-redundant system. To order the upgrade kits, please contact your local Honeywell Customer ‘Service office and request the necessary quantity of kits. The upgrade kit model number for the 620-0080 processor module is a 220-0080-3. The upgrade kit for the 621-9939 Serial Link Module is a 221-9939-2. All 620-0080 Processor modules will ship from the factory at V.R 3.0 with expanded serial diagnostics enabled. Modules purchased as spares or replacements will include parts and instructions to down-grade the Processor module to V.R 2.6 if the customer's installation requires this. Those users wishing to upgrade older 620-0080 Processor modules to V.R 2.6 can still order Model # 220-0007 upgrade kits. Honeywell Iaduetrial Automation and ControlTDC 3000 ‘TAB PD 48 CUSTOMER PAGE ‘A05 (L) RESOURCE MANUAL DATE 3 JUL 1994 FN:161 FN Date: 15 MAR 1994 PROCESSOR FIRMWARE UPGRADE -V.R 3.2 Background Changes Action Conditions exist in 620-12/16/36 and 9010-012/016/036 processor firmware versions 2.0 through 3.1 - causing outputs to momentarily clear when the processor mode is changed from program to run mode, even though the processor is configured to freeze /O during the mode transition. The specific conditions are: « If the processor key switch is moved rapidly from Program through Disable to Run with Software Program mode disabled * If Software Program mode is released while the key switch is in the Run or Run/Program position “Either of these conditions will cause: * The field outputs which had been frozen in the ON state will momentarily clear before resuming the ON state dictated by controlling inputs. Version 3.2 corrects this condition. ‘Additionally, a change has been made to the firmware which controls the processor communications port when it is configured for Modbus RTU protocol and full duplex/point to point operation. The change allows the port to wait indefinitely for the receiving device to assert its CTS signal in response to the RTS signal from the processor comm port. This change was done specifically to allow modems adequate time to assert their control lines. Since many users place a jumper between the comm port's RTS and CTS lines when operating in a point to point mode, they will NOT notice any change in operation. Previously, an RTS/CTS fail safe timer was incorporated to assure that the ‘comm port's RS 485 transmitter would go to a tri-stated mode should the intended receiving device not assert its CTS signal in an allotted time. This had been incorporated so that a multidrop configuration would not hang up should a single device fail to respond. The RTS/CTS fail safe timer is still functional when the port is configured for Modbus RTU and half duplex/muttidrop operation. UPGRADES: Processor upgrade kits can be ordered by contacting your local Honeywell Customer Service Center. The respective processor and upgrade kit model numbers are listed below: Processor Model # Upgrade Kit Model # 620-1200 or 9010-012 220-1200-3 620-1633 or 9010-016 220-1633-3, 620-3632 or 9010-036 220-3632-3,'FAB__PD 1805 (M) PAGE _2 DATE _29 DEC 1994 620-0080 PROCESSOR MODULE WITH V.R 3.0 FIRMWARE, Continued Logic Manager(LM) IMPORTANT Temporary Work Around Upgrade Kit Ordering Instructions LCS 620-35/25, or $9200/9100 Systems: Connect MS-DOS Loader package, select [F1] Loader Monitor from the Main Menu, then press [Enter] at the 620 Selection Menu. Above the Title Block Display, at the top of alist of processor configuration data is a field labeled "Revision Level". If the ‘number to the right of "Revision Level is 55, then the processor has version 3.0 firmware. To use a Universal Station to check a Logic Manager Revision Level, select "Detailed Status Display’, "LM Status", then "Hardware Status". Check the field labeled “Revision Level if a value of 55 is shown, the processor has version 3.0 firmware. All systems identified as having version 3.0 firmware must have the temporary work around shown below installed. The following four steps should be taken to temporarily allow continued safe ‘operation of the 620-0080 with 3.0 installed. 1. Allpoints configured in LM's, CCC(Series 9000), PCS, PCX, MAS or other supervisory systems that access register 4352, must be changed to use other addresses. 2. The MS-DOS Loader Data Change function and Data Display functions should not be used to access register 4352. Either of these functions ‘can write a value to register 4352 that will cause a failure. Until corrected firmware is installed use of these functions should be carefully monitored. 3. Change Relay Ladder Logic, as required, to remove all references to register 4352. 4, Program the following line of logic as the last executed line of logic in the program. This will prevent any ladder logic that writes to the register from causing a failure. tt will NOT prevent the Loader or option modules such as LMM, LPM or DCM from writing a value to register 4352 that can cause a failure. 4352 [k2]-- == ($2) 0 0 Model number 220-0080-3 Upgrade Kits with version 3.1 firmware will be supplied at no charge. You may order at any time by preparing the following information and contacting your local Honeywell office. 1. P.0.# or SID 2. Quantity and serial numbers, if possible, of boards to be upgraded. 3. Contact name and shipping address. Moneywell Industriai Automation and ControlTDC 3000 ‘TAB P18 CUSTOMER PAGE ‘AOS (M) RESOURCE MANUAL DATE 29 DEC 1994 FAQ FA Date: 31 OCT 1994 620-0080 PROCESSOR MODULE WITH V.R 3.0 FIRMWARE Products Logic Manager systems, LCS 620-35/25 systems and 220-0080-3 Affected Upgrade Kits shipped between 09/23/93 and 10/25/94. in addition, any Logic Manager system, LCS 620-35/25 system or S9200/9100 system upgraded to V.R 3.0 will be affected. Note: $9200e/9100e systems are NOT affected. Problem Due to an error in the diagnostic code in version 3.0 firmware, the processor may incorrectly detect a processor fault and cause the system to fail. This unnecessary failure will only occur i the processor has V.R 3.0 firmware and a value of 256, or its multiples (512, 768, 1024 etc.), appears in register 4352. In a non-redundant Logic Manager, LCS 620-35/25 or '$9200/9100 system this would result in a loss of view and loss of control. In redundant systems the lead wil fil, transfer control to the backup and then the backup will fail. The result is the same loss of view and loss of control. However, in both redundant and non redundant systems the /O will folow the operation specified in the Serial VO Module or Parallel VO Module DIP switch settings and either clear or freeze the current output status. IMPORTANT! All modules identified as having version 3.0 firmware must be upgraded by ordering and installing an upgrade kit. See ordering instructions below. Identifying Products Affected: 620-0080 Modules manufactured with firmware version 3.0 are marked with a silver Processor label showing "V.R 3.0" on the front of the component cover just below the Modules model number label. If the module is not marked in any way, remove the component cover, locate chips US and U17(chips with labels). If these chips have any other marking other than *3.0" following a five digit part number the module does not have version 3.0 firmware. Continued on next pageTDC 3000 TAB PD 18 CUSTOMER PAGE ‘ADS (ND RESOURCE MANUAL DATE 18 MAY 1996 ERRONEOUS CLEARING OF OUTPUTS Affected 620-12/16/36 Processors Products 9010-012/016/036 Logic Processors Background This bulletin is intended to inform users of a situation which has the potential to erroneously clear outputs in 620-LCS or $9000e systems. In order for this situation to occur, a processor module must be at version V.R 3.1 or greater, a ladder logic sequencer instruction in the users program must be driven to an invalid step number (either step #0 ora step that doesn't exist in the sequencer) and the user must be displaying the sequencer circumstances, outputs programmed below the sequencer in the ladder logic program will be cleared as the user lines up/down through the ladder program. Action In order to avoid this situation, it is recommended that users insure that sequencer step number registers do not reset to a zero value or do not exceed the number of programmed steps in the sequencer table. Moneywell Industrial Auconation and contro?TDC 3000 TAB PD 18 CUSTOMER PAGE AO8 (A) RESOURCE MANUAL DATE 6-1-88 Field Notice 60 Issued 1-4-88 ‘SYMPTOM: 620-0036 AND 627-7037 POWER SUPPLIES It has been observed that the BATTERY PASS LED will come on if the battery is installed backwards in the 620-0036 and 627-7037 power supplies. The IPC 620 installation manual (Form No. 620-8996) page 34; indicates that "THE BATTERY MUST BE INSTALLED CORRECTLY IF IT IS TO ACT AS A BACKUP FOR THE SYSTEMS’S RAM MEMORY". Both of these power supplies will be corrected such that the BATTERY PASS LED will not come on if the battery is installed backwards. No known instances of this have occurred in the field. ‘This Field Notice is issued to make you aware of a potential problem and that something will be done to correct the problen. Honeywell Industrial Automation Systems Division Honeywell Industrial Services DivisionTDC 3000 TAB PD 1a CUSTOMER PAGE Aos (B RESOURCE MANUAL DATE 6-1-88 Field Notice 81 Issued 5-27-88 ITEM: BACKGROUND: ADVICE: 620-0036 POWER SUPPLY LOADING Revision F (12/87) of the 620 Installation Manual incorrectly describes the +5v Dc output of the 620-0036. This power supply is capable of providing 9.5 amps of +5v DC to modules located in the option slots and I/O slots of the processor rack. The total rated +5v DC output of this supply for all processor rack modules is 15 amps. There are certain processor rack configurations that will exceed the 15 amp rating of this supply when using the published unit load figures for individual processor rack modules. The published unit load for a module is not the typical load but represents a statistical "Average Worst Case" current requirement for the module. In actual application the 620-0036 will accommodate all known processor rack configurations to date. For instance, a 620-35 system with 24k memory, 4k register, 2 SIMS, 2 HIMS, 1 RCM, and 1 DCM requires 18.4 amps of +5v DC according to published unit load figures. The measured +5v DC power requirement for this system was 12.6 amps. It is IPCO’s opinion that the 620-0036 has adequate power to handle all known processor configurations available to date. Discretion should be used however, when configuring systems that exceed the 15 amp rating using published unit load figures. DON’T PUSH IT! Honeywell Industrial Automation Systems Division Honeywell Industrial Services DivisionTOC 3000 TAB PD 18 . CUSTOMER PAGE __A08 (C) _ RESOURCE MANUAL DATE __11-10-88 _ Field Notice 84 Issued 7-8-88 ITEM: 620-0036 POWER SUPPLIES BACKGROUND: The subject power supply has the potential to create memory Changes or processor lock ups in 620-20 and 620- 30 systems. Changes were made to this supply in December, 1986 that improved the regulation and also improved the amount of time that the 5 VDC could hold up. The changes were not made at that time because of a known problem, but because a vendor quit manufacturing a component for the supply. Failure reports from field installations led to an investigation which isolated the problem to the early supplies with the now obsolete component. Not all of these supplies generate this type of failure. If the AC power to the supply decays in less than 16 milliseconds the problem will not appear. However, if the AC power is removed but takes longer than the 16 millisecond time frame to decay the problem MAY occur. ADVICE: If you suspect that you are having this problem with a 620-20 or 620-30 system that shows the above symptoms, you should call Honeywell York Technical Services. and Honeywell Industrial Autenation Systems Division Moneywel Industrial Services DivisionTDC 3000 TAB pb 1a CUSTOMER . PAGE _A0@ (E) RESOURCE MANUAL DATE __11-30-92_ FA:8 FA date: 11-2-92 620-0047 24 VDC PS, POSSIBLE ERRATIC OUTPUTS IN SER. I/O SYS Background Two 620-0047 Power Supplies have been found to have a failure of the 5 VDC regulation circuitry, due to severe aging and temperature degradation effects on a specific component. This failure is most likely to occur with an ambient air temperature of 30 degrees C or greater and loading of the power supply that would result from the installation of certain option modules. Modules capable generating the necessary load are the 620- (0081 HIM, 620-0042/43/48/52 CIMs, 620-0072 LPM and 620-0071 LMM. ‘The result of this failure is that the 5 VDC output rises until the Over Voltage Protection circuit shuts the supply down. When a 620 LCS system with Serial /O has a 620-0047 experiencing this over voltage condition, the 621-9939 Serial Link Modules may begin to incorrectly address the I/O status tables on the SLM before an Over Voltage Protection shutdown occurs. The net result is that input status and field outputs may change state without being directed to do so by input modules or the execution of the ladder logic program. ‘A620 LCS system with only parallel /O and a similar power supply failure, will not experience any effect on I/O status until processor diagnostics or the Over Voltage Protection shut down the system. Either of these shut-downs will cause the V/O to Clear or Freeze depending on the DIP switch settings of the 621-9930/9937 PIOM. The failure to regulate the 5 VDC output has been traced to an optical isolator in the feed back path of the power supply regulator circuit. This component has, in both cases, been found to have degraded sufficiently to prevent the regulation circuitry from operating properly. Both power supplies found to have this problem were manufactured in 1987. The component vendor changed the production process for the faulty part in 1989, resulting in a component whose aging and temperature degradation characteristics will not cause a problem in the regulator circuit. However, the power supply vendor and component vendor have been unable to identify precisely the date after which the new component was used in the manufacture of the 620-0047. Continued on next pageTAB _PD 18 AOS (E PAGE _2_ DATE __11-30-92 620-0047 24 VDC PS, POSSIBLE ERRATIC OUTPUTS IN SER. I/O SYS, CONTINUED Action Inspection Instructions All 620-0047 power supplies, except those with the HRO1 marking on the front plate, must be inspected to determine if they have the older optical isolator and thus, the potential for this failure. Even though 620-0047 power supplies manufactured from 1990 to present probably do not contain the suspect part. Honeywell recommends that all supplies be inspected. Instructions for performing the inspection are attached to this alert. Power supplies found to contain the potential for failure will be exchanged, at no charge, for factory tested 620-0047 power supplies. If @ replacement power supply is needed, please contact Honeywell with the following information and reference this FIELD ALERT. 1. Purchase Order Number 2. Serial Number of each 620-0047 to be replaced, if available. 3. Desired quantity and delivery schedule. 4. Shipping Instructions. Instructions for Inspection of 620-0047 Power Supplies IMPORTANT! Inspection should be performed by qualified personnel. All 620-25/35 LCS Systems: The 620 LCS ladder logic program will be lost, when the 620-0047 is removed from the rack. Non-Redundant Systems: The 620 LCS processor will cease to operate and all /O will Clear or Freeze, depending on the DIP switch settings of the 621- 9930/9937 PIOM, when 24 VDC is removed from the 620-0047 input. Be sure to save the current program before removing power from the supply. Be prepared to reload the program after power is applied to the system. Redundant Systems: Do not remove power from the processor currently in the Lead. Be sure that the processor containing the 620-0047 to be inspected is operating as Back-Up before beginning the inspection procedure. If the 620-0059 Redundancy Control Module in the B/Non- Preferred processor (normally the Back-Up) is set to enable program down load, a copy of the program in the Lead processor will be automatically down loaded to the B/Non-Preferred processor when power is restored. However, when the power supply is removed from the A/Preferred processor (normally the Lead), with the RCM set to prevent a program down load (typical setting), the ladder logic must be re-loaded before the process can be returned to service. Continued on next page Moneywell Industriai Autonat ion and ControlTAB pb 18 AQS (5) PAGE _3_ DATE __11-30-92 620-0047 24 VDC PS, POSSIBLE ERRATIC OUTPUTS IN SER. I/O SYS, CONTINUED Inspection Instructions, Continued gaeps |. Remove 24 VDC power from 620-0047 input. . Disconnect and insulate power cable. 3. Remove 620-0047 from processor rack. }. Remove round metal hole plug in power supply component caver. .. Use board component layout Figure 1, to locate and identify U1. Ut is directly below the "R4” silk-screened on the board. If necessary, remove component cover completely to complete inspection. If U1 is a black plastic Dual In-line Pin package this supply may experience the failure previously described and should be returned to Honeywell as described in the FIELD ALERT. If Ut is a white plastic DIP package this power supply may be returned to normal use. Using a permanent marker, mark the face plate of the module with "HRO1™. This will identify the module as having the correct, ‘component and indicate that the inspection has been completed. . Install component cover and return supply to service or return to Honeywell based on the results of step 5. CHIP UNDER eat BOTTOM 620-0047 POWER SUPPLY BOARD - COMPONENT SIDE Figure 1 Honeywell Industrial Autenation and ControlTDC 3000 TAB PD 1s CUSTOMER PAGE Al4 (A RESOURCE MANUAL DATE 6-1-88 Field Notice 63 Issued 1-15-88 ‘ITEM: 620 REDUNDANCY/SERIAL I/O ADVICE: 620-0059 Redundancy Control Modules must have Revision B firmware for operation with serial 1/0. This firmware will also enhance operation with 620-0081 hiway interface modules by allowing diagnostic information to be passed from the back-up HIM to the lead HIM. RCM’s shipped after 12-15-87 has Revision B firmware. The firmware code of any RCM can be determined by the letter suffix (B) appearing on the EPROM located at U13. RCM’s can be upgraded by ordering the RCM upgrade kit 220-0014. The serial numbers of the RCM’s to be upgraded and the end user name and location must be provided at the time the upgrade kit is ordered. Honeywell Industrial Automation Systems Division Honeywell Industrial Services DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE Ald (B)___ RESOURCE MANUAL DATE 6-2-88 Field Notice 69 Issued 2-24-88 ADVICE: 620-0059 REDUNDANCY CONTROL MODULE 620-0059 RCM’s with a firmware code of "A" or "B" (RCM’s shipped prior to 2-10-88) will not operate correctly with the program download option enabled. Two operational errors have been identified. They are as follows: ae A simultaneous power up of redundant processors while in the run mode could result in both processors failing diagnostic tests resulting in loss of control. 2 When a loader is monitoring a logic line in the lead processor and the backup is placed in the run mode the program transfer from lead to backup processor will incorrectly transfer the logic associated with the monitored line resulting in invalid memory in the backup processor. Both of these errors are encountered when the program download option is enabled. ‘The most expedient measure to correct these two errors is to disable the program download option by setting switch 1, position 4 on the RCM to the closed/on position. A permanent solution via new firmware will be made available through an upgrade kit in the very near future. Information on the upgrade will be announced in a future Field Notice. Honeywel Industrial Automation Systems Division Honeywel Industrial Services DivieionTDC 3000 TAB PD_18 CUSTOMER PAGE Al4 (Cc) RESOURCE MANUAL DATE 4-88 Field Notice 78 Issued 4-20-88 SUBJECT: REDUNDANCY CONTROL MODULE 620-0059 UPGRADE A new RCM upgrade kit will is available to correct RCM operation errors described in Field Notice 69 (PD 18 A 14 B) dated 2-24-88. 620-0059 RCM’s and 220-0014 RCM upgrade kits shipped from York will have the new "Cc" level firmware. All other RCM’s and RCM upgrade kits shipped prior to 4-20-88 must be updated by ordering the new kit. RCM’s can be checked for their revision level by inspecting the EPROM located at socket U13. The letter suffix on the EPROM must be "C" or higher. The EPROM contained in the upgrade kit can be inspected in a like manner Honeywell Industrial Automation Systens Division Honeywell Industrial Services DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE Al4 (D) RESOURCE MANUAL DATE 5-31-88 Field Notice 80 Issued 4-27-88 ‘ITEM: 620 REDUNDANT PROCESSORS ADVICE: The RCM User Manual indirectly states that a 620-0085 TocM is required when using serial I/o with redundant processors. (See page 31 under the Serial Link Status.) NOTE: This Field Notice is being issued to state directly that a 620-0085 IOCM is required when using serial I/O with redundant processors. The consequence of not abiding by this rule is that serial link faults will not be detected by the RCM thus perventing a switchover to the backup processor and serial 1/0 Link. Honeywell Industrial Automation Systems Division Moneywell Industrial Services DivisionTDC 3000 TAB PD 1a CUSTOMER PAGE __Al4 (E) RESOURCE MANUAL DATE ___6-20-88 _ Field Notice 83 Issued 5-27-88 ITEM: ‘BACKGROUND: ADVICE Redundancy Control Module/Augmented Run Programming Firmware revision "C" for the 620-0059 will send the progran memory checksum of the lead processor to the back-up processor during a program download. The backup will use this checksum for comparison when it calculates its own checksum upon assuming the run mode. The purpose of this procedure is to insure that both processors have identical programs. When an augmented run mode programming change is made to the lead processor a new checksum is calculated. The calculation process can be lengthy (i.e. many seconds). If an augmented run mode change is made to the lead processor then the backup processor should not be put into the run mode, thus causing the download, until the lead processor is finished calculating a new checksum Failure to do so will cause a checksum error in the backup processor when it is placed in the run mode. Recovery requires clearing memory of the backup and initiating another progran download. The status of the lead processor checksum calculation can be determined by monitoring system status register 2391 using the following logic line. If the contents of this register is 128 then the calculation is in progress. If the register value is 32896 then the calculation is complete and a program download to the backup processor can be performed. 2391 8000 — [Pun] ————___—(s2) — 1 senonK The 620-0080 Processor must be Revision 50 or greater for proper checksum operation. See field notice #71 (PD 18 A05 A) Woneywel Industrial Automation Systems Division Woneyuell Industrial Services DivisionTDC 3000 . TAB PD 18 CUSTOMER PAGE __Al4 (F) RESOURCE MANUAL DATE ___11-21-88 _ Field Notice 89 Issue Date 9-15-88 ITEM: 620-0059 Redundancy Control Module BACKGROUND: There is a possiblility that both redundancy control modules in a redundant system will erroneously detect serial link faults and shutdown their respective processor (even though serial 1/0 may not be installed) when power to an I/O rack containing a parallel bus selector module is cycled. Recovery is accomplished by cycling power to each processor which clears the serial I/O fault. This condition, while not prevalent, has been verified and should therefore be corrected by updating the RCM firmware to revision 1.4. 620-0059, RCM’s and 220-0014 RCM upgrade kits shipped from York after 9-15-88 will have the 1.4 revision firmware. ACTION: RCM’S can be checked for their revision level by inspecting the EPROM located at socket U13. The letter suffix on the EPROM must be "D" or higher. The EPROM contained in the upgrade kit can be inspected in a like maner. Honeywell Industrial Autonation Systeas Division Honeywell Industrial Services DivisionTDC 3000 TAB PD 1s CUSTOMER PAGE Al4 (G) RESOURCE MANUAL DATE 11-29-89 IPC620 FIELD BULLETIN 8-18-89 SUBJECT: USING PARALLEL I/O IN REDUNDANT IPC 620 CONFIGURATIONS When a parallel I/o rack in a redundant IPC 620 system loses power for any reason, both the A (lead), and B (backup) Processors will assume I/O power-fail status. In this case, neither processor executes the control program, and system 1/0 (with the exception of the 1/0 in the rack with no power) will either clear or freeze depending on the DIP switch settings on each Parallel I/O Module (PIOM). When power is returned to the failed I/o rack, the lead processor will react by initiating a program download to the backup (if enabled), and will clear all non-retentive outputs and timer accumulators. Since outputs cct directly via information transfer modules such as the HIM (620-0081) are considered non-retentive, these will be cleared during the Powerup process. The loss of both processors during a single 1/0 rack power failure can be avoided by using the IPC 620 serial 1/0 system instead of the parallel 1/0 system. A redundant IPC 620 system using serial I/O can be configured to react in several different ways to an I/o rack power failure, most of which do not involve the loss of the entire IPC 620 system. Honeywel Industrial Automat ion and Control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE Al4 (H) RESOURCE MANUAL DATE 12-19-89 IPC620 FIELD BULLETIN 11-1-89 SUBJECT: Redundancy Control Module (RCM) Compatibility This Bulletin addresses the compatibility issues raised by the introduction of Version 2.X ROMs. In light of the situations presented below, and in order to guarantee proper performance, a previously unstated requirement is now made: REDUNDANT 620 PROCESSOR SYSTEMS MAY ONLY USE REDUNDANCY CONTROL MODULES WITH THE SAME VERSION AND REVISION LEVELS. Within Version 1.X, the ROM underwent several firmware changes, designed to correct problems that were seen in that version. Compatibility within the Version 1.X family of RCMs was assumed because the changes made did not significantly challenge the functional operation of the module. Making this assumption, testing to guarantee compatibility between different revisions of the Version 1.X RCM firmware was not performed. The changes made to the RCM for Version 2.0 do significantly change the functionality of the module. Version 2.0 RCM firmware includes several new functions that allow the module to commmicate with other modules (Second RCM, SLM, 620 Processor) and provide a higher level of system diagnostics. At the same time, the changes made to the RCM firmware demand that another RCM with the same level of firmware be present in the redundant processor. Another point of concern is that the factory considers the Version 2.0 RCH firmvare to be the only shippable version of firmware for the RCM. This implies that an RCM returned for repair may enter the factory with Version 1.4 firmware, and, along with other necessary repairs, be returned with Version 2.0 firmware. This does not cause any problem until the 2.0 ROM is installed in a system and expected to operate properly with any Version 1.X RCM as a partner. Testing done to date has shown that there are cases where the new RCM can confuse the older one, and vise versa. To assist users in avoiding potential misapplication of the RCM, a Version 2.0 upgrade kit is available at a cost of $100.00. The kit contains material for upgrading one RCM, and can be ordered using model number 220-0059-2, This kit is offered for an indefinite period of time, and will be available December 1, 1989. 1.X RCMs returned by customers for repair with be repaired and upgraded to 2.0. A 220-0059-2 kit will be supplied at no extra cost with the returned module so that its potential partner may also be upgraded Honeywell Industrial Automation and Control DivisionTOC 3000 TAB PD 18 CUSTOMER PAGE Al4 (1 RESOURCE MANUAL DATE 09-28-90 FIELD NOTICE #126 Issued 4-3-90 ITEM: 620-0059 Redundancy Control Module Firmware V.R 2.2 ‘A number of changes have been made to the firmware of the 620-0059 Redundancy Control Module (RCM). The modifications, described below, have been incorporated into V.R 2.2 of the ROM’s firmware 1. USER SWITCHOVER INHIBIT Changes were made which, when used with V.R 2.1 of the 620-0081 Hiway Interface Module, will inhibit a user initiated switchover when the Lead HIM’s database has not been transferred to the backup. For additional details on this, please see Field Notice #125, 620-0081 HIM V.R 2.1. 2. SERIAL LINK FAULT FAILOVER The RCM detects a Serial Link Fault by monitoring the Input/PULL Data Ready (IPDR) bits in the SIM status byte at address 2040. The RCH considers a change from ON to OFF of these bits to be serial link shutdown, If one or more of these bits has gone from ON to OFF in the running Lead system, a failover should occur if the other processor is available to take control of the process. In all previous revisions of the RCM, the RCM did not monitor these bits in the Lead-No-Backup (LNB) or Non-Redundant (Program Mode) states. Because of this, if an RCM was powered-up in the LNB state and a link shutdown occurred while the RCM was still in the LNB state, the RCM would not recognize the change in the IPDR bits, and would not note that a serial link fault had occurred. Due to this problem, a failover would not always occur as expected when the backup was brought on-line. Changes were made in V.R 2.2 to ensure that the IPDR bits are always correctly monitored by the RCM, thus ensuring that a failover will always occur if a serial link is shutdown and a running backup is available. Furthermore, the RCM will now annunciate a serial link fault in ANY mode EXCEPT Lead No-Backup. Honeywell Industrial Automation and Control DivisionTAB _PD 18 A14 (I) PAGE _2 DATE _9-28-90 3. SLM DATA DURING FAILOVERS When a switchover occurs, the SIM recognizes the change in state of the ROM inputs to the SLM and turns its Input/PULL Data Ready (IPDR) bits OFF to indicate that input and PULL data in the SIM’s data table is in the process of being brought up to date. Due to a change made in V.R 2.0 of the firmware, the state of the Lead Select cable was not being changed to Lead immediately on a failover from the Non-preferred ("B") processor to the Preferred ("A"), which caused a delay in the IPDR bits being turned off This would allow the "A" processor to execute its program and update real 1/0 based on SIM 1/0 data from the last time the unit was in the Lead. The net effect of this was that, during a "B" to "A" failover situation, it was possible for the 620 which was becoming the Lead to perform one or more Program scans with invalid data from the SLM. This problem has been corrected in V.R 2.2 of the ROM. RETROFIT RECOMMENDATIONS Because it is very difficult to predict the possible consequences of bad data on a failover, it is strongly recommended that all users of RCM V.R 2.0 firmvare and serial I/O update their RCMs to V.R 2.2 at their earliest convenience. Users of V.R 1.3 (Rev.C) or 1.4 (Rev. D) may wish to update to V.R 2.2 to ensure recognition of all link faults. If should be noted that V.R 1.2 (Rev.B) and lower revisions are obsolete and should not be used. Users of 620-0081 HIMs should plan to update their HIMs at the same tine as their RCMs (see F/N #125). Finally, the user is reminded that RCM versions used in a redundant pair MUST match; i.e., if one RCM has V.R 2.X in it, then its redundant partner must also have V.R 2.x. UPGRADE KIT INFORMATION Upgrade Kit 220-0059-2, V.R 2.2, contains the firmvare changes to correct the problems described in this Field Notice. Orders are now being accepted for the upgrade kits, which will be available at no charge for a period of 90 days beginning May 15, 1990. Customers should contact Customer Service in York at (717) 71-8111 or (800) 344-1909 to place upgrade kit orders. When placing an order, customers should be prepared to provide a no-charge purchase order number, the quantity of upgrade kits required, and an approximately date the kits will be needed. For orders placed after August 15, 1990, the upgrade kit will have a price of $100.00. The user must order at least two kits to implement the retrofit recommendation. Noneywel Industrial Autonation and Control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE __A15 (A) RESOURCE MANUAL DATE ___6-4-88 _ Field Notice 79 Issued 4-20-88 ‘ITEM: 620-0081 HIWAY INTERFACE NODULE REL 1.3 BACKGROUND: The firmware has been enhanced to indicate a PLC backplane failure detection and PROGRAM mode detection/notification. - The PLC backplane failure detection is indicated if during "ON LINE" processing of the database, the communication between the HIM and the processor ceases. A notification is made to the Data Hiway by setting the "Slot Failure Flags" and the "PC Link Failure" residing in the Reserved Data Base. - Detection and notification of PROGRAM mode occurs only during the "ON LINE" processing by setting the "Slot Failure Flags" while in PROGRAM mode. Upon entering DISABLE or RUN mode these flags are restored to their original value. SYMPTOM: Before this correction, writes to the HIM Data Base from the Hiway were being incorrectly stored in the Image Memory. The result of this action was that instead of writing a change to address 16 for instance, the change would be written to address 32. NOTE: In the 620-10/15, a faulty backplane interface may be signalled when no fault has occurred. This has been corrected. The HIM can be upgraded by ordering the 220-0013 Upgrade Kit Honeywel Industrial Automation Systems Division Honeywell Industrial Services DivisionTDC 3000 TAB ___ppD 1s CUSTOMER PAGE A15 (B) RESOURCE MANUAL DATE 12-18-89 Field Notice 113 Issued 9-18-89 ITEM: Use of the 620-0081 Hiway Interface Module in Applications with the Hiway Coupler Module A condition has been identified that may cause a performance problem when using the 620-0081 Hivay Interface Module in conjunction with a Hiway Coupler Module. The last bit of data transmission from the HIM may extend for a time period longer than the desired one micro-second. This “long” bit may then be interpreted as two bits by the Hiway Coupler Module, resulting in Data Hivay communication errors. THIS CONDITION ONLY EXISTS IN APPLICATIONS WHERE THE 620-0081 HIWAY INTERFACE MODULE IS USED WITH THE HIWAY COUPLER MODULE. CUSTOMERS WHO USE THE 620-0081 HIWAY INTERFACE MODULE AND DO NOT HAVE A HIWAY COUPLER MODULE ARE NOT AFFECTED BY THIS FIELD NOTICE, AND SHOULD NOT BE EXPERIENCING ANY PROBLEMS. Customers who are using a 620-0081 Hiway Interface Module in a Data Hivay configuration with a Hiway Coupler Module should follow the field exchange Procedure outlined below. A replacement 620-0081 HIM will be provided, at no charge. 1. Contact Pat McGuigan at the Honeywell ICD Customer Service Department, and obtain a Returned Goods Authorization number (RGA number). Customer Service will require a purchase order number (specifying no-charge), the quantity and serial numbers of the 620-0081 Hivay Interface Modules involved in the exchange, as well as the date required. 2. Upon receipt of the purchase order, a replacement unit(s) will be scheduled to ship in time for the customer's scheduled shutdown to swap the unit(s), and invoiced on a "memo billing” basis. 3. After the customer returns the old unit(s) to us, full credit will be applied for the new unit(s) that were shipped against the memo billing. The RGA number must accompany the returned units to receive credit. ‘YOUR COOPERATION IS REQUESTED IN SCHEDULING THE EXCHANGE UNITS FOR SHIPMENT FROM ‘YORK IN A TIMELY MANNER CONSISTENT WITH THE SHUTDOWN AND SWAP OF THE UNIT(S) AT THE CUSTOMER SITE, AND IN RETURNING THE OLD UNITS(S) IMMEDIATELY. This exchange program is available free of charge to customers using a Hivay Coupler Module on the same Hivay with a 620-0081 Hiway Interface Module, and who notify Customer Service PRIOR TO NOVEMBER 30, 1989. The exchange can take place at a later date convenient to the customer's schedule for shutdown. Honeywell ICD Customer Service may be reached at telephone mumber (717) 71-8111, 8:00 a.m, to 5:00 p.m., Monday through Friday. Woneywell Industrial Automation and Control DivisionTDC 3000 ‘TAB PD 18 CUSTOMER PAGE A15 (C) RESOURCE MANUAL DATE 12-18-89 Field Notice 114 Issued 9-18-89 ITEM: 620-0081 Hiway Interface Module - Firmware Release 2.0 Corrections have been made to the firmware to improve the performance and correct functional problems of the 620-0081 Hiway Interface Module. The changes effected by this release are numerous, and are described below. While not all users will be experiencing the problems addressed by this release, the new release is considered MANDATORY, and will be offered free of charge to customers ordering this upgrade kit. We encourage all Honeywell locations to contact their customers and advise them of the availability of this upgrade. This release corrects the following conditions: 1. The Alarm-Change Notify/suppress functions has been enhanced to provide for independent control of each Hiway Box. Previous releases limited this function to the module level only. 2. A means of tracking a redundant configuration’s status for use in detecting a redundant switchover in Hiway Gateway and 4500 applications has been added. 3. A five second timeout is now present on the General Report Buffer. This function is used in recovering from a lost echo following a report buffer call-up. + A correction was made to the interface microcode report echo receive path. A condition had existed that contributed to the "1198 Alarm Failure" message in previous releases. 5. Analog Alarming was modified to include both Hi/Lo alarms and significant change alarms in the same alarm entry when both occur simultaneously. Previously, significant change alarms were not being included in this’ case. 6. The Command Disagree Reporting function was corrected to include all digital state changes from open to closed and alarm state changes. Previously, a state change may not have been reported when using Digital Composite points with the command Disagree alarm format specified. Honeywell Industrial Autonation and control DivisionTAB _PD 18 A15_(C} PAGE _2 7. The interface handling was modified so that if the Poll/call- Up mechanism of one box fails, the other three will continue to operate normally. 8. Improvements have been made in the Data Base transfer from lead to backup HIM. This change prohibits a redundant pair of HIM’s from operating together with different versions of firmware. BOTH HIM’s IN A REDUNDANT SYSTEM MUST BE UPGRADED FROM VERSION 1.X TO VERSION 2.0 (THIS RELEASE) AT THE SAME TIME. One upgrade kit should be ordered per Hiway Interface Module. A redundant configuration (2 HIM’s) requires two upgrade kits. AS STATED ABOVE, BOTH HIM’s IN A REDUNDANT CONFIGURATION MUST BE UPDATED AT THE SAME TIME. A VERSION 2.0 HIM WILL NOT OPERATE PROPERLY WITH A VERSION 1.3 (OR EARLIER) HIM. To order the upgrade contact Pat McGuigan at Honeywell ICD Customer Service Department, telephone (717) 771-8111. Specify upgrade kit model number 220-0081-2. This upgrade will be available October 15, 1989, with two to four week delivery. A PRICE OF $100.00 WILL BE CHARGED FOR ALL ORDERS RECEIVED AFTER DECEMBER 31, 1989. Honeywell Industrial Automat on and Control DivisionTDC 3000 a TAB PD_18 CUSTOMER PAGE A15_(D) RESOURCE MANUAL DATE ___9-11-90 FIELD NOTICE #125 Issued 4-3-90 ITEM: 620-0081 Hiway Interface Module (HIM) V.R 2.1. a) A number of changes have been made to the firmware of the 620-0081 Hiway Interface Module (HIM). These modifications, which include enhancements and corrections to problems, are being incorporated into V.R 2.1 of the HIM. USER SWITCHOVER INHIBIT DURING DATABASE TRANSFER In order for both HIMs in a redundant system to work with the same database, the database in the Lead HIM is transferred to the Backup HIM, one box at a time, when the Backup processor enters the RUN mode. If a switchover occurs before the database transfer has been completed, any box which is not fully transferred will enter a RESET state, causing a loss of view to all points associated with the RESET box(es). To restore this view, the user must reload the RESET boxes. A change was made to the HIM which, when used with V.R 2.2 or higher of the RCM, will inhibit a user initiated switchover before all HIM box database have been transferred to the backup HIM. This will prevent the user form generating switchover which could result in a loss of view. User initiated switchovers are those requested by the Lead Request buttons on the ROMs, by setting contact 4112, or by an option module PUSHing 0055H (85) to system status table location 2262. It should be noted, however, that a system generated failover will still occur even if the boxes have not been transferred. It is felt that the failover, necessary to ensure proper system operation and control of 1/0, should be a higher priority than the potential for a temporary loss of view to a portion of the process. ALARM FAIL ERRORS A problem was noted in the V.R 2.0 revision of the HIM which could cause an 1198 Alarm Fail error on a box when a Database Clear operation had been performed on one of the other boxes in the same HIM. This problem, which was not present in V.R. 1.X, was caused by an error in the routine which determines which HIM box would respond to a POLL command. Under certain circumstances, it was possible for the routine to miss one or more boxes after a Database Clear had been performed to a different box on the same HIM. This problem has been corrected in V.R 2.1. Moneywel Industrial Automation and Control DivisionTAB _PD 18 A15 (D) PAGE _2_ DATE _9-11-90 3. FAILOVER DURING DATBASE TRANSFER In all previous versions of the HIM, the Database Transfer operation was a byte-by-byte copy of a range of memory from the Lead HIM to the Back-up HIM, A byte roughly in the middle of this block of memory contains information on the status of the HIM. If a failover occurred AFTER this byte had been transferred, but BEFORE the rest of the information for the box was transferred, it was possible for a box in the new Lead HIM to ha an incomplete database, but a status word which had been transferred that said the box was "OK". Thus, a box could end up in RESET while the Hivay Status display vould indicate "OK" for the box. This problem has been corrected in V.R 2.1 firmware by masking the transfer of the status information from the Lead to the Backup HIM. 4. MORE THAN TEN WRITES PER PROGRAM SCAN In all previous revisions of the HIM, the user was limited to 10 writes to Analog Output or Timer/Counter values in a given processor scan. Any additional writes would be lost without notification. With V.R 2.1, this restriction is now removed, and any writes beyond 10 will result in a BUSY response. The user should attempt a delayed retry if a BUSY response is received. It should be noted that it would generally not be feasible for a user to send 10 writes in a single processor scan from an operator station, due to the number of keystrokes involved; however, it would be possible with an Application Module. DELAY OF IMAGE TABLE UPDATES ON RETENTIVE SCAN A change was made to delay the initial update of the HIM's Tmage Table for 6 Memory Word Zero (MWZ) windows after a retentive scan of the IPC 620 Processor. This change will prevent the potential for a temporarily inaccurate reading of I/O after a retentive scan, which could have occurred if the HIM began updating its Image Table before an Input Status Scan was performed by the IPC 620. Delaying the Image Table updates for 6 MZ Windows guarantees that an Input Status Scan will occur BEFORE updates to the HIM take place RETROFIT RECOMMENDATIONS Since problems 2 and 3 above have the potential to cause substantial operator confusion, it is recommended that users update their 620-0081 HIMs to V.R 2.1 at their earliest convenience. Users of redundant systems should plan to update both 620-0081s in each system at the same time; similarly, they should update their 620-0059s (see PDI8A (I)) at the same time. UPGRADE KIT INFORMATION Upgrade Kit 220-0081-2 V.R 2.1, contains the changes described above. Orders are now being accepted for the upgrade kit, which will be available at no charge for 90 days beginning May 15, 1990.” Customers are requested to contact Customer Service in York at (717) 771-8111 or (800) 344-1909 to place upgrade kit orders. Customers should be prepared to provide a no-charge purchase order mumber, the quantity of upgrade kits needed, and an approximate date the kits will be needed when placing an order. For orders placed after August 15, 1990, the upgrade kit will have a list price of $100.00. Honeyvel Industrial Automation and Control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE __A15 (E) RESOURCE MANUAL DATE __9-28-90 _ FIELD NOTICE #132 Issued 8-24-90 ITEM: 620-0081 Hiway Interface Module V.R 2.2 Several processor compatibility problems have been noted with certain versions of the 620-0081 Hiway Interface Module. Furthermore, a shortcoming in the current user manual for the HIM has been noted. This Field Notice is intended to describe the problems, to describe what has been done to correct the problems, to provide recommendations for upgrade of affected units, and to inform you of the manual deficiency. PROCESSOR COMPATIBILIT 01d 620-10/15 Processors: A firmware problem introduced in V.R 2.0 of the HIM made the module incompatible with old 620-10/15 processors. The incompatibility caused the HIM to misread information, including the number of I/o points in the system. When the HIM begins to process I/O points, a fatal program error occurs. This bug made V.R 2.0 and 2.1 of the HIM. incompatible with the old versions of the 620-10 and 620-15 processors. The processors, 620-1030, -1031, -1032, -1530, -1531, and - 1532, were not manufactured after the 620-0081 HIM was introduced in early 1987; however, installations may exist where the HIM was retrofitted into old 620-10/15 systems. If an attempt is made to update one of these installations to V.R 2.0 or 2.1, as recommended in Field Notices #114 and #125, the HIM’s boxes will not exit from the RESET state after they have ben loaded from the Hiway, and the PASS LED on the HIM will go out. Since the misreads only occur with the OLD 620-10-/15 processors, no other processors are affected by the problem, which has been corrected in V.R 2.2 of HIM. 620-06 Processor: A separate problem in all versions of the 620-0081 HIM caused the HIM to misread the number of I/O points in the 620-06 processor. The misread would cause a fatal program errcr when point processing is started in the HIM by the Enable Processing or Box Load command, causing the boxes to go into RESET at the Hiway status display and causing the HIM PASS LED to go out. The problem would ONLY occur in the 620-06 processor, and has.been corrected in V.R 2.2. Moneyvell Industrial Automation and Control DivisionTAB _PD 18 A15 (E)_ PAGE _2 DATE _9-28-90 620-26/36 Processors: The new 620-26 (which will only be available in Europe) and 620-36 Processors are not compatible with earlier releases of the HIM. V.R 2.2 of the HIM is fully compatible with the 620-26 and -36 processors. It should be noted that these problems occur only in the old 620-10/15, the 620-06, and 620-26/36 processors, respectively. No other processor incompatibilities exist in any version of the HIM, and no other changes have ‘been made in this revision of the HIM. For this reason, there is no need to update HIMs from V.R 2.1 to 2.2 UNLESS they are installed in one of these processors. All 620-0081 HIMs and 220-0081-2 HIM Upgrade Kits shipped from York after August 15, 1990 will use V.R 2.2 of the firmware. V.R 2.2 is fully compatible with V.R 2.0 and 2.1 in redundant configurations The requirement of Field Notice #114, to update all HIMs to V.R 2.0 or higher, still stands. Updating a HIM to the new V.R 2.2 fulfills this requirement. Customers who have V.R 2.0 or 2.1 installed in old 620-10/15 processors, or who have any HIM version less than 2.2 in a 620-06 installation, may order upgrade kit 220-0081-2 from Customer Service for no charge until Novenber 30, 1990. After that date, a charge of $100 will be applied to each kit. To order upgrade kits, contact Pat McGuigan at (717) 771-8111 with a no charge purchase order, and the serial number of the old 620-10/15 or 620-06 Processor with’ which the HIM is being used. HIM 01 Table 8 on page 22 of the current HIM User Manual, form #620-8981 Rev B, does not state the settings for SW2 and SW6 when the HIM is installed in 620-11, -14, -16, -26, or -36 processors. SW2, which is to select battery backup from the processor, should be set towards the edge of the board, because these processors supply a battery voltage to the HIM for memory retention during power down conditions. SW6, which selects whether +/- 12V or +/- 15V is being used, should be set avay from the board edge to select +/- 15V supplied by the 620-0041, -0046, and -0083 Processor Power Supplies used in these systems. This information is presented in tabular form below. Switch 620-11, -14, -16, -26, -36 sw2 Toward Board Edge swe Away From Board Edge This documentation deficiency will be corrected in the next release of the HIM User Manual Honeywell Industrial Autonation and Control DivisionTDC 3000 TAB PD18 CUSTOMER PAGE AIS) RESOURCE MANUAL DATE 7 FEB 1994 LCS 620 HIWAY INTERFACE MODULE V.R 2.3 Problem f more than 32 simultaneous alarms are generated, there is a possibility that the HIM will not correctly report them all to the hiway gateway. The missing alarms will not appear in the alarm summary display or be journaled. There will be an inconsistency between the PV and the HIGHAL parameter in the HG as viewed from the Detail Display or the points. Action Upgrade the HIM to firmware version 2.3 to correct this problem. The upgrade kit number for version 2.3 firmware is 220-0081-2. Contact your local Honeywell office to order the upgrade.TDC 3000 TAB PD 1s CUSTOMER PAGE A16 (A) RESOURCE MANUAL DATE 20-90 Field Notice 73 Issued 3-14-88 620-0048 DATA COLLECTION MODULE SYMPTOM: A problem exists in the 620-0048 Data Collection Module with Revision E or lower that affects communications back to the host. If the DcM is processing a first instruction which requires it to fetch a significant amount of data from the PLC and, by doing so, takes more than the normal amount of PLC backplane time; and in the meantime a second instruction is received before the response of the first has been completely transmitted back to the host, the DCM will not respond to the second instruction. In most applications this typically will result in a timeout of the program requesting the information unless there is a built in "retry" feature. In Support Controller applications it will result in a [MD 5 1] communications error which is a response from the MDA to the LIP indicating a failed response to a pass through message. ADVICE: Upgrade kits to fix this problem are available. They can be obtained free of charge until further notice by ordering Model Number 220-0004: 620-0048 Upgrade Kit. This kit will bring any DCM up to revision "F" and/or a V.R. of 2.2. The revision of any DCM can be identified by the ROM number itself, or by using the DCM "Read DCM Status" command from the Host system. In the near future, DCMs will have V-R. labels affixed to the faceplate of the product as it is manufactured indicating a V.R. of 2.2. Outdated versions of ROMs in socket U4 will be numbered 31033(A-E) while the new versions to be placed in socket U4 will be numbered 31033F or, when V.R. is applied 62299. Moneywel Industrial Automation and Control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE Al7_(A) RESOURCE MANUAL DATE ___9-28-90 FIELD NOTICE #131 Issued 8-27-90 ITEM: ‘DC 3000 LOGIC MANAGER UPGRADE TO RELEASE 301 HARDWARE REVISION HRO4 FIRMWARE VERSION V.R 2.5 BACKGROUND: All TDC 3000 Logic Manager Systems with Logic Manager Modules, model no. 620-0071 with hardware revision HRO2, HRO3, or ere absent of a HR number are affected. A hardware and software upgrade have been developed to correct several functional problems detected in the initial release of Logic Manager and to provide a performance improvement. This upgrade consists of an new Logic Manager Module M/N 620-0071 designated hardware revision HRO4, firmware revision V.R 2.5, and TDC 3000 maintenance Release 301. | The hardware and software must be installed together. The customer must refer to the TDC 3000 Release 301 Release Notas far complata details of how to perform the upgrade. THE FOLLOWING PERFORMANCE IMPROVEMENTS ARE IMPLEMENTED: UCN parameter accesses were not being serviced at the design specification of 400 accesses per second. This revision improves the Logic Manager's performance and provides UCN parameter access in excess of 400 accesses per second. 2. The initial release of Logic Manager only provided 2,000 processing units for user data points. This release improves the Logic Manager's point processing capability by providing a 40% increase to 2,800 available processing units. Point processing capability has increased with all point types, with the exception of the digital composite point, which now uses more processing units per second. The method for calculating the point mix remains unchanged. Multiply the number of points of a specific type by the number of processing units per point. Perform this calculation for each point type. Add the sub-totals of each point type together to find the grand total, which must be equal to or less than 2,800. Configurations larger than 2,800 cannot be loaded. Honeywell industrial Autonation and Control DivisionTAB 17_ (a) PAGE _2 DATE _9-28-90 PROCESSING UNIT POINT TYPE MAXIMUM ALLOWED VALUE PER POINT DIGITAL INPUT = 1866 1.3 DIGITAL OUTPUT - = 46000 0.7 DIGITAL COMPOSITE - = 306 9.2 ANALOG INPUT 2/SEC SCAN - - 127 22.0 ANALOG INPUT 1/SEC SCAN - = 256 11.0 ANALOG OUTPUT 2/SEC SCAN - 482 5.8 ANALOG OUTPUT 1/SEC SCAN = 965 2.9 LINKAGE (PEER-PEER) - 200.0 TIMER = 700 4.0 FLAG = 1024 * N/A NUMERIC - = 1026 * N/A *FLAG and NUMERIC points do not consume processing units. IN ADDITION 10 THE PERFORMANCE IMPROVEMENTS, THE FOLLOWING FUNCTIONAL PROBLEMS HAVE BEEN CORRECTED: 1. DIGITAL COMPOSITE POINT A new parameter, "OPFINAL” has been added to reflect the actual output state. The digital outputs are now read back to display the actual output state on the group display. In Release 300, the actual state of the output had to be monitored with an I/O bit external to the DC point. A user configurable “none” state has been added so that undefined states do not cause a "Bad Control" alarm. This is beneficial when a pulsed output is used. A "Bad Control” alarm has been added and will be annunciated when the digital outputs are in an undefined state. The Override Interlocks now can control the digital outputs. An un- commanded Disagree alarm is generated after two consecutive OP/PV miscompares occur. The Override Interlocks are NOT to be used for critical or safety interlocking. Critical or safety interlocking should be implemented in the ladder logic program. 2. DATABASE SECURITY IMPROVEMENT In Release 300, if the NIM failed while the LM was being restored from the checkpoint file, thus resulting in only loading part of the LM's database, this IM will generate a message to the operator. This did not, however, prevent the operator from issuing the RUN command or Prevent the operator from checkpointing a partial database. Release 301 hhas an enhancement that clears out the Logic Manager's database should only a partial database be downloaded due to a NIM or UCN communications failure, thus preventing an operator from checkpointing a partial database or issuing a run comand with a partial database Moneywel Industrial Automat on and Control DivisionTAB _PD 18 Al7 (A PAGE 3 FIELD UPGRADE EXCHANGE ORDER PROCEDURE The upgrade procedure involves the exchange of the Logic Manager Module (4/N 620-0071) with a replacement. To determine if you need an upgrade, examine the front panel of the Logic Manager Module, model no. 620-0071, immediately above the model number. Only those Logic Managers without an HR label, or versions marked HRO2 or HRO3 are affected. Release 301 software and new Logic Manager hardware will be provided at no charge. Customers should coordinate the software upgrade to Release 301 with the physical installation of the new Logic Manager Module. Customers who purchased TDC 3000 Logic Manager Systems from Phoenix will be notified of the upgrade order procedure by the Honeywell Customer Satisfaction Department in Phoenix, AZ. Call Dick St. Amant (602) 863-5160 or Frank Merrill (602) 863-5241 if you have any questions regarding Release 301 upgrade. The York Customer Service Department cannot answer any questions regarding TDC 3000 Release 301 software. Honeywell domestic in-house users, international regions, and the Phoenix factory who ordered Logic Manager Modules directly form the York factory should contact Pat McGuigan at the York Customer Service Department, (717) 771-8111. Supply a no-charge purchase order number when ordering. Credit for the new unit will given when the old unit is returned. You must obtain a Returned Goods Authorization (RGA number) to insure proper credit before returning any material. In order to accommodate your requested delivery date for the new module (which is to coincide with your release 301 upgrade plan) and to facilitate a smooth upgrade, please place your order AS SOON AS POSSIBLE, specifying your required in-plant date. Every effort will be made to meet your requirements. This upgrade is MANDATORY for all affected Logic Manager Modules, and will be available free of charge until December 31, 1990. Old versions of Logic Manager Module (620-0071, HRO2 and HRO3), will not be supported after December 31, 1990. Honeywel Industrial Automation and control DivisionTDC 3000 TAB __pD 18 __ CUSTOMER PAGE __Al7 (B) RESOURCE MANUAL DATE __10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS Background’ Many of the 620 LCS modules have DIP switches. The following information shows typical settings and gives information on how to customize settings. The letters show the switch position and why i's in that position: “F" The first group of switch settings shown are the Factory settings. When a new or replacement board is received these are the typical settings. They are indicated by an "F" in the switch diagrams below. “R" The second array of settings are the basic settings Recommended by Honeywell. These settings are shown by an "R" in the diagrams. It may be necessary to deviate from these settings due to the requirements of individual sites. These settings are intended as a starting point for typical LM installations. "0" Where elections are necessary to customize the settings for particular installations the settings are indicated by an “O" as Optional settings. A brief description of the meaning of the DIP switch settings is included at the end of this article. Figure 1 shows what a typical DIP switch looks like. The switch lever is moved towards the circuit board for ON and away from the circuit board for OFF. Figure 1 shows pos 1 & 4 towards the circuit board to be ON and pos 2 &3 away from the circuit board to be OFF. OFF ON Circuit Board Figure 1 Continuedon next page Woneywell iadustrial autonstion and ControlTAB _PD 18 Al7 (B PAGE _2_ DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued LMM DIP Switch Settings ‘The sw positions 2, 3, 4, 5 and 6, on the Non-Preferred LMM, determine the LMM's node address on the UCN. Refer to the Logic Manager Installation ‘manual (LM20-300) for the correct address settings. The Non-Preferred sw Positions 2, 3,4,5 and 6 must agree with those on the first LMM. Sw Position #1 indicates this is the Preferred LMM. Turning sw #1 "ON" identifies this as the Non-preferred or redundant LMM. ‘SW2 (factory setting) 12345678 CFLFTFIFIFIFIF[F] orF ON ‘SW2 (for the Preferred LMM) ‘SW2 (for the Non-Preferred LMM) 12345678 12345678 RIO O} Of O} OF R] R} OFF Of Of of Of of R OFF ON R ON PLDM DIP Switch Settings The RCM has a built in 250 mis watch dog timer. If a tighter tolerance is required then set the PLDM DIP switches accordingly. The amount of time is controlled by PLDM positions 2, 3, and 4 of SW1. The "OFF" position adds zero msec. to the timer; the "ON" position adds 20 msec., 40 msec. or ‘80 msec. for the respective DIP switches. (Factory Settings) swt sw2 12 3 4 1234567 8 — ‘Woneywet) Industrial Automation and ControlTAB __PD 18 A17(B) 3 DATE. 1 OCT 1994 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued PLDM DIP The following settings of SW1 & SW2 are for both the Preferred and Non- Switch Settings, Preferred LMs. Continued swt sw2 1234 1234567 8 JCor [ [rR I not_] OFF ON R OL Of Of R] used] On SLM DIP Switch Use the SAME settings for the option positions 5 and 6 on the Non- Settings Preferred SLM as you used on the Preferred SLM. When considering the option settings for positions 5 and 6 consult the throughput explanation in Appendix F of the 620-8996 manual. SW1__ (Factory settings) 12345678 TFTFIFIFIFIFIF[F] OFF ON ‘SW1 (for Preferred LM's) ‘SW1 (for Non-Preferred L's) 12345678 12345678 O]_[R] OFF RERTRTR] [Ol] [R] OFF R[RIR[ RO, [R[ [ON of [RT [on RCM DIP Switch —SW1 settings: Settings . Factory settings Preferred LM's Non-Preferred LM's 12345 123465 12345 CLI OFF RT_|_] OFF R]_| OFF FIF[FLON R[RL_[R[R| ON R[R[RT [RON oneywell Industriai Autonation and ControlTAB PD 18 A17 (8) PAGE _4 DATE __1 OCT 1994 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued SIOM DIP Switch The first switch position (#1) establishes the starting address for the particular VO rack. The switch positions are true or active when they are in the ON" position. The switches start with 8 for position 1 and go up by 8s Settings 8, 16, 32, e setting is for 32 points per slot. (Factory Settings) swt sw2 12345678 12 3 4 (FIFIFIFIFIF[F LF] OFF F [not] F ON [F[_fsed] Positions 3, 4 and 5 control the number of V/O points per . Refer to the SIOM manual for the necessary settings. The factory OFF ON NOTE: position 3 is not used. SIOM DIP Switch /O RACK BOARDS Example o|~2 o]s= BS ols ol ol o ols ol 29 2 3 NOTE: position 3 is not used. This yields an address of 32. Below are the positional (starting) address values associated with SW1. The starting address is the sum of all the switches "ON". The chart shows the value added by each switch which is *ON" 475 7 64_[ 128 | 256 [512 3 ADRValue[ 8 | 16 | 32 Continued on next page oneywell Industrial Automation and ControlTAB pb 18 Al7 (B PAGE _5_ DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued EDM DIP Switch Settings Information Switch Descriptions Enhanced Diagnostic Module located in left most of any I/O file itis to monitor. For redundant LM systems always set Position 1 "OFF" and Position 2 "ON" to obtain the required 4.5 second time-out for redundant operation. Position 3 set "ON" is the proper setting for a Serial /O system. 12.34 ow OFF R[R[R| ON indicates seffing for serial I/O system. + Additional information on the switch settings and their meanings for the following modules can be found in the publications of the Logic Manager Instruction manual (LM20-300 or 400) in section 7. EDM LM Module LMM PLDM RCM SIOM SLM Below is a brief reference for various switches and their uses. The factory settings are shown in BOLD print. Any required (mandatory) settings are in Italics (OFF/ON). * LMM Mother Board SW1 Settings ‘These switches establish the back panel address for the LM; in ALL cases the LM back plane address MUST be 1+. For the required LMM ‘SW2 DIP switch UCN address settings refer to the Logic Manager Installation Manual table 7-7. The setting of this switch establishes the UCN addresses for the LMs. swt BACKPLANE POSITION - STATE ADDRESS 1 2 Continued on next pageTAB _pD 18 A17 (B: PAGE _6_ DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued Switch Below is a brief reference for various switches and their uses. The Descriptions, factory settings are shown in BOLD print. Any required (mandatory) Continued settings are in italics. * PLDOM FUNCTION Disables the processor scan loss function Enables the processor scan loss function ‘Adds 20 milliseconds to the RCM timer Doesn't add any time to the RCM timer ‘Adds 40 milliseconds to the RCM timer Doesn't add any time to the RCM timer ‘Adds 80 milliseconds to the RCM timer Doesn't add any time to the RCM timer ‘sw2 POSITION FUNCTION 1 Disables the processor VO. Indicates there are no VO cards in the Processor rack Enables the processor I/O. Indicates the processor rack contains VO cards Indicates there are only 16 point /O modules inthe processor rack Indicates that only 6 point /O modules are in the processor rack VO racks clear or freeze their outputs according to the SIOM freeze/clear DIP switch settings when the software PROGRAM mode is used ‘When in software PROGRAM , all outputs remain in their last state regardless of the SIOM freeze/clear setting Enables the FORCE function for ladder logic Disables the FORCE function Enables the following data changes in the RUN mode: change RM Table values, change sequencer register values, change constant values. Disables the above changes in the RUN mode. Enables on-line programming in the RUNPROGRAM mode Disables on-line programming ‘Clear the processor rack outputs if a fault occurs Freeze the processor rack outputs if a fault occursTAB _PD 18 Al7 (8) PAGE _7 DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued SLM DIP Switch The first four switch positions operate as pairs as shown below. Switch Settings positions 1 and 2 apply to channel 1; switch positions 3 and 4 apply to channel 2 FUNCTION The channel continues to operate if a channel fault occurs due to Power failure; serial link time-out or the receipt of two consecutive serial data errors. The channel ceases operation if a channel fault occurs Both channels on SLM cease operation ifa channel fault occurs Both SLM channels shutdown, plus the CLROL line on the /O bus is set - resetting the parallel /O and causing a second SLM, if present, to have its corresponding SIOMs clear or freeze data depending on the SIOM SIP switch settings Service one PUSH/PULL card per VO rack each scan Service all PUSH/PULL cards per I/O rack each scan Identifies the SLM as the second SLM in the card file Identifies the first , or only, SLM in the card file Indicates a redundant serial /O system Indicates a non-redundant serial /O system Enables the factory tests Disables the factor Noneywell Industria) Automation and ControlTAB _PD 18 Al7 (8B) PAGE _8_ DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued Redundancy —_—_There can only be one RCM in any rack and the only permitted address for Control Module the RCMis 0. Settings FUNCTION ‘Address = 0. This is the ONLY permitted address for the RCM “This position is not permitted ‘Address = 0. This is the ONLY ermitted address for the RCM This position is not permitted The RCM is in the secondary position (Non- preferred rack) “The RCMis in the primary (Preferred rack) Prohibits program down load function into this processor Permits program download into this processor Enables the primary request switch, SERIAL VO DIP switch 1 just sets the starting address for the /O rack that SIOM is in. Module See the table on page 4 for setting the starting address value. See below for the function of DIP switch 2. DIP switches 3, 4, & 5 set the number of VO points that will be in each of the 12 V/O slots. 2 switch positions are required for each V/O slot. Each DIP switch controls 4 V/O slots. ae FUNCTION POSITION Clear outputs and PUSH data with: 1. SW2 position 2 closed and /O fault occurrence 2. Loss of SLM communications 3. extemal power failure 4, processor in PRG or DISABLE mode 5 Freeze outputs and PUSH data with conditions above Recognize I/O card fault and respond according to above Ignore output module fault NOT USED Factory test position, Continued on next page oneyweil Industrial Automation and ControlTAB _PD 18 Al7 (8) PAGE _9_ DATE _10-20-92 SUGGESTED SWITCH SETTINGS FOR LM INSTALLATIONS, Continued ‘SERIAL VO Two switch positons are used to set the number of I/O points in each Module, slot. Each DIP switch controls 4 /O slots. The "(1)" and "(2)" indicate Continued the two positions that control the 1/O point count for the slot indicated by the left side of the table below. The slot letter and the "(1)" & "(2)" are silkscreened next to the three DIP switches (SW3, SW4, & SWS) on the circuit board. DIP SWITCH NUMBER OF I/O POINTS SET POSITION CONTROLLING vo fr BY SWITCH STATE ‘SW4 ENHANCED Switch positions 1 and 2 operate together to identify the Watchdog Timer DIAGNOSTIC _ selection. Switch Settings FUNCTION 1.74 second time-out 200 ms time-out 435 second time-out (required for redundant Serial systems) ‘490 ms time-out ‘Identifies serial 1/0 operation Identifies parallel VO operation ‘A data bus or control line fault de-energizes the internal relay immediately ‘Signal from a SIOM, PIOM or LM de-energizes the relay ‘oneyweii Todustrial Avtomtson and GontrotTDC 3000 TAB PD 1g CUSTOMER PAGE Als (A) RESOURCE MANUAL DATE 12-21-90 620 Les FIELD ALERT 11-2-90 SUBJECT: 620-0072 LPM/Series 9000 Invalid Data Reads A Problem has been discovered with the 620-0072 Loop Processor Module (LPM) and its operation with Revision 2.X Series 9000 software. The cause of the problem is a Samsung KM6264 RAM that, according to Samsung, will intermittently return invalid data during a long-word read operation from the microprocessor. The effect of the defective component typically shows up as an inability to download configuration software to the LPM from the Series 9000 Supervisory Station; the "BUS" LED on the LPM will typically remain illuminated and the Logic Processor may appear to be “hung up.” Because the problem is intermittent, it is possible that the download operation will perform successfully, although continued operation of the module may result in undefinable action of the Series 9000 software caused by the invalid data returned from the Samsung RAM. To date, however, no such conditions have been reported by Series 9000 customers. Even though this design flaw exists in the Samsung part, only a small percentage of the Series 9000 systems in operation may be affected. Because the failure mode occurs only during a long-word read operation, systems running Version 1.X configuration software are not susceptible to this problem; long-word reads were not implemented in the software prior to Version 2.0. Additionally, the operation of the Samsung part is dependent on the electrical characteristics of other components in the LPM, therefore, only a portion of all Series 9000 systems may contain a “sensitive” Samsung RAM that could result in incorrect operation of the system. Furthermore, Samsung is only one of a number of vendors whose RAM have been used in the LPM. Only the Samsung part contains a problem. Because of the potential problems which exist due to invalid data reads, Honeywell placed all of the 620-0072 LPM modules on HOLD, and replaced the Samsung KM6264 part with another manufacturer's component. The new manufacturer's 6264 RAM has been rigorously tested to ensure that it does not have the same design flaw as the Samsung part. To correct 620-0072 modules which are out in the field and could contain the “sensitive” Samsung KM6264 RAM, Honeywell will immediately implement a no-charge exchange program. Replacement modules shipped from the factory after October 5, 1990 will not have the Samsung KM6264 part, and will be designated as a hardware revision (HR) of 03 or higher. The hardware revision label will be applied to the LPM's front plate and shipping container for easy identification of updated modules. ‘Any LPM less than HR revision 2.0 and V.R less than 1.5 should be replaced. Please call Pat McGuigan, Honeywell's Customer Service Representative, at (717) 771-8111, and have available the quantity and serial numbers of modules to be exchanged and a no-charge purchase order. For customers who choose to upgrade but will not have an opportunity to exchange modules until a scheduled plant shutdown, please call as soon as possible so the proper arrangements can be made to have a sufficient quantity of modules available for the scheduled plant shutdown Honeywell will offer a normal one-year warranty on all exchanged 620-0072 modules Noneywel Industrial Automation and Control DivisionTDC 3000 ‘TAB PD 18 CUSTOMER PAGE BO1 (A) RESOURCE MANUAL DATE 2-14-89 Field Notice 92 Issue Date 10-88 ITEM: 32 Pt. I/O Cardslots with 6, 8 or 16 pt Modules Installed BACKGROUND: Clarification needs to be made regarding the use of an I/0 rack card slot that is set for 32 point 1/0 operation and when a non 32 point digital card is installed in that slot. There is a fundamental design difference between 6, 8 and 16 point 1/0 cards as compared to the 32 point 1/0 cards that can cause problems if the following information is not understood. ‘The following chart shows the resultant INCORRECT ADDRESS data, in terms of addresses 0-31, that will be sent to 6, 8 or 16 point cards installed in a 32 point card slot after the initial correct address data has already been strobed to the card. 32 POINT CARD SLOT OPERATION CARD INSTALLED: WILL INCORRECTLY RECEIVE ADDRESSES: 6 POINT 16 - 21 8 POINT 16 - 23 16 POINT 16 - 31 1/0 SYSTEM EFFECT: ACTION: In Serial 1/0 systems the SIOM updates all outputs assigned in the rack, not just those executed in the control program. The 6, 8 or 16 point card addresses will be changed as per the data sent out by the SIOM to update the remaining addresses of the 32 peint card slot. This data sent to the addresses discribed in the chart above will normally be OFF unless the customer uses these “unused real 1/0" of that card slot for internal coils. In this case, the real addresses of the 6, 8 or 16 point card will be controlled by the state of those "internal coils” per program execution. : In parallel 1/0 systems, the problem only appears when these "unused real 1/0" of that card slot are used for internal coils. The 620 1/0 was not designed to mix modules in this fashion. There is no hardware fix for this situation. The only solution is to inform users of this situation and follow this simple rule: DO NOT PUT A 6, 8 OR 16 POINT DIGITAL I/O CARD IN A CARDSLOT THAT IS CONFIGURED FOR 32 POINT I/O OPERATION. Honeywell Industriat Automation systens Division Honeywell industrial Services DivisionTDC 3000 TAB ___PD 18 _ CUSTOMER PAGE __B03 (A) RESOURCE MANUAL DATE ____6-4-88 Field Notice 66 Issued 2-2-88 ITEM: BACKGROUND: NOTE: Precautions Against Battery Drain On I/O Modules Installed In Augmented I/O Racks This field notice describes a procedure to modify certain augmented I/o racks with battery-backed I/O modules installed in them. The racks affected by this field notice are listed in table 1. Modification to the resistor packs in the augmented rack must be performed if: (1) an augmented rack containing battery-backed I/O modules has never been upgraded (see table 1 to determine if your rack requires this upgrade), or (2), an augmented rack containing battery-backed 1/0 modules has been upgraded using upgrade kit 221-0002 revisions A or B. Revisions A and B of upgrade kit 221-0002 do not instruct. the user to perform all the modifications necessary to completely upgrade the augmented rack. See the attached sheets for instructions on how to identify and upgrade the augmented racks that are used with battery-backed 1/0 nodules. The following instructions tell how to upgrade the resistor packs or you can obtain new resistor Packs by ordering the Augmented Rack Update Kit (221-0002) The current revision of this kit is c. Honeywell Industrial Autonation Systems Division Noneywel Industrial Services DivistonTAB _PD 18 BO3 (A) PAGE _2_ DATE __6-4-88 RESISTOR PACK UPDATE FOR AUGMENTED RACKS VO modules (such as the 621-0012 ASCII ‘Communication Module) that access the upper ‘bus on an Augmented Rack, lose battery power when installed inthe rack. ‘These VO modules can be installed in an ‘Augmented Rack (Le. a rack with an upper bus on the backplane) ¥ certain precautions are observed. Folow the procedure below to guard against loss of battery power. DETERMINE WHICH RACK MUST BE UPDATED ‘The folowing racks have augmented backplanes and must be updated o prevent loss of battery power inthe ACM: (623-0093 620-10/15 Hall Rack 620-0091 620-10/15 Standard Rack 621-9992 621 VO Standard Rack 1. Determine the rev. level ofthe rack’s backplane by locating the revision label. The revision label is located on the let side of the + ackplane in standard racks (621-9992 and (620-0091) ard on the right side of the half rack (620-0093). See Figure 1. 2. Determine the Augmented Rack must be Updated by reterting to Table 1 TABLE 1 - RACK REVISION LEVELS UPDATE THE AUGMENTED RACK ‘There are two methods of updating an Augmented Rack: 1) obtain the AUGMENTED RACK UPDATE KIT ‘by ordering model number 221-0002, or 2) remove ‘esistor packs and cut the appropriate pins as outined in the folowing procedure. NOTE the AUGMENTED RACK UPDATE KIT is. sed, folow only the instructions included with the Kt. Locate the resistor pack(s) that must be Updated. These resistor packs are not labeled ‘and must be located according fo their postion fon the backplane, Refer to Figure 1. ‘Standard racks (620-0091 and 621-9982) each have two resistor packs that must be updated. ‘The 620-0083 Hall Rack has one resistor pack that must be updated ‘Update one resistor pack at atime to avoid Confusion. Remove one resistor pack, cut the proper pin (300 Figure 1), and reinstall he pack ‘Repeat this procedure for each resistor pack ‘that must be updated. Mis recommended that resistor packs are removed with an IC extraction ‘tool. Cut the proper pin(s) as close to the body ‘of the chip as posse. Reter to the figure ‘below for pn locations on individual resistor = fi Z evoununs ‘TEST THE UPDATED AUGMENTED RACK ull athe sogmert jumpers off the backplane (Of the rack. The 621-9982 rack has two Sets of |brmpers ard the 620-0089 ard 620-0091 racks Contain one set of jmpers. Refer to Figure 1 for jumper cation Inger an ASCII Communiation Module nto the VO slot on the far lft si ofthe updated rack. ‘Aso, install the rack power supply. Remove the battery rom the ACM. Automat ion Systens Di Honeywell Industrial Services DivisionTAB _PD 18 BO3 (A: PAGE DATE __6-4-88 WARNING ‘TROUBLESHOOTING Removal of the battery will erase all data ‘Stored in the battery-backed RAM memory. 3 8. Apply power tothe rack. 9. Check the BATT LED on the installed module, {the LED is OFF, the update procedure was. ‘successful forthe resistor pack in that segment. Hf the LED is ON, the update Procedure was unsuccessiul: refer to the TROUBLESHOOTING section. 4 10. tthe user is updating the 620-0083 Ha Rack, 15. the update procedure is complete, the rack power can be tumed OFF and the battery ‘should be installed in the module. ifthe user is Updating a standard rack (621-9992 or 620- (0091) then tum the rack power OFF, remove ‘the ACM from the Augmented Rack and install ‘the medule into the VO slot on the far right side ‘of the Augmented Rack. 11. Tum the rack power supply ON. 12, Check the BATT LED on the installed module. {the LED is OFF, the update procedure is ‘complete; the rack can be tuned OFF and the battery should be installed in the module, tt ‘he LED is ON, the update procedure was Lnsuccesstul; refer to the ‘TROUBLESHOOTING section. ‘Tum the rack power OFF and remove the ‘ASCII Communication Module Remove the resistor pack common tc the ‘segment that faled the update test. Note ‘thatthe that rack has only one segment. in standard racks, the VO slot on the far left side corresponds tothe left segment and the VO slot on the far ight corresponds tothe right segment. ‘The Update test failed because the pn on the resistor pack was sill making cortact wth the socket. Cut the pin off as clese to the body ofthe chip as possibie without damaging the chip. Reinstall the resistor ‘Pack and the module, then test as bere. ‘Note that both the lef and right segments of a standard rack must be tested. ithe update test continual fails or a resistor pack is ‘damaged during the update procedure, call Honeywel's IPC-York Customer Technical ‘Services Department or order the ‘AUGMENTED RACK UPDATE KIT (mode! 221-0002), sequoe ron Pack Soares Gotan Cotrecmen eH Goo oo000 ooo! Ul ED BAGK ee ‘orarabe! ment FIGURE 1 - BACKPLANES ON AUGMENTED RACKS. Noneywel Industrial Automat on Systens Division Honeywell Industrial Services DivisonTDC 3000 TAB PD 18 CUSTOMER PAGE BO3_(B) RESOURCE MANUAL DATE 3-4-91 620 LCs FIELD BULLETIN 11-20-90 ITEM: Detection of Loss of +/- 15V in I/O Power supplies Analog inputs and outputs in the 620 Logic Controller system utilize power from +15VDC and -15VDC sources on the 1/0 Power Supply. These voltages, which are referred to as auxiliary supplies, are used as references for analog value scaling and to provide power for analog output signals. While a green 5VDC LED indicates an OK status for the primary voltage source, no external indication of +/- 15V status is available. Although auxiliary voltage problems are relatively rare, loss of either the +15V or -15V signal can result in inaccurate analog input values and incorrect. analog output signals. The purpose of this Field Bulletin is to describe methods of detecting auxiliary voltage supply problems. It should be noted that +/- 15V supply problems WILL NOT cause problems in digital I/o cards. Several types of analog input modules for the 620 LCS check the auxiliary supplies for adequate voltage and provide an error indication if problems are detected. These modules are the 621-0014 Thermocouple Input Module, the 621- 0022A and 621-0022V Isolated Analog Input Module, and the 621-0020 Universal Analog Input Module (UAIM). By checking these modules for appropriate error codes, it is possible to determine the status of the +/- 15V supplies in the racks in which the modules are installed. Note that the obsolete 621-0000 Analog Input Module and the 621-0010 Analog output Module both use the auxiliary supply voltages, but do not perform diagnostics on them. In order to have +/-15V @iagnostics on the 621-0000 and 621-0010, the user should monitor the auxiliary supplies at a 621-0014, -0022, or - 0020 input module within the same 1/0 rack. Honeywell Industrial Automation and ControtTAB _PD 18 B03 (B) PAGE _2_ DATE _3-4-91 621-0014 Thermocouple Input Module: As mentioned in the 621-0014 User Manual (Form No. 621- 8996), an error code is provided at input channel 6 of the T/C Input Module. A PULL from this location will be 128 or greater if the +/- 15V is lost. Thus, the following line of logic will set bit 2099 on if a +/- 15v problem exists in the rack which contains a 621-0014 installed at least significant address (LSA) 128: LSAt5 +/- 15V t/e error problem register rack 128 ERROR 15V BAD 133 2099 =+ [PUL] ---- [>]---~ [K2 ] ------------------------- 222-222 = (0) == 1 127 621-0022 Isolated Analog Input Module The 621-0022 User Manual (Form No. 621-8988) describes two methods of detecting auxiliary voltage problems. First of all, the 620-0022 module will report a card fault to the processor if a +/-15V problem is detected. To determine if the card is reporting a card fault, the user should check system Status Table (SST) location 2415 to see if the Card Fault Count is non-zero; if it is non-zero, check SST locations 2417-2431 to determine if a Card Fault Address matches the address of the card. The second method of checking for auxiliary voltage problens with a 621-0022 module is to set SW1 and sW2 both oN. This method will cause the 13th bit of channel values to be set when a problem with the auxiliary supplies is diagnosed. The user then only needs to compare one channel on the module to determine if the value is 4096 or greater. Thus, the following line can be used to determine if an auxiliary voltage problem exists in an I/O which contains a 621-0022 with LSA = 128: +/- 1sv problen rack 128 ch. 2 15V BAD 128 2099 Woneywel Industrial Automation and Control DivisonTAB _PD 18 B03 (B: PAGE _3 DATE _3-4-91 621-0020 Universal Analog Input Module The 621-0020 UAIM provides an indication of +/-15V supply failure though I/o Status Bit LSA+23. When this bit is turned on by the module, it indicates that the +5V, +15V, or -15V supplies to the module are not within a tolerable range. Thus, the following line is sufficient to detect loss of +/-15V in a rack containing a 621-0020 with an LSA of 128: +5V_ or 5/+/-15V 4+/-15V problem error rack 128 LSA+23 15V BAD 151 2099 -Eoi wannnnnnnnnnnn nnn nn nnnnnannnnnnn (== Since the loss of +/-15V signals can cause inaccurate analog output signals as well as bad analog input data, it is recommended that problems with the supplies be brought immediately to the operator’s attention through some type of high priority alarm. As analog input and output data are both determined as a percentage of the +/-15V range, it is effectively impossible to place analog outputs into’a known state without knowing the precise levels of the +/-15V supplies. For this reason, if a problem is found with the auxiliary supplies in a rack, devices controlled by analog outputs within that rack should be placed into local manual mode or be shut down until the defective supply can be replaced, and analog input values from that rack should be flagged as bad until the problem is corrected. It should be noted that one common cause of +/-15V problems is power supply overloading. Before installing any system using analog inputs and/or outputs, use the "620 System Unit Loads" table in the 620 LCS Installation User Manual, Form No. 620-8996, to determine the total load placed on the +5V and +/-15V sections of the power supply for each rack. Total loads must not exceed the output capability of the rack power supply in use. Overloading of the +/-15V sections will cause +/-15V supplies to go out of tolerance, and hence to cause inaccurate analog input and output values. Honeywell Industrial Automation and Control DivisionTDC 3000 TAB__PD 18 CUSTOMER PAGE ___BO04 (A) _ RESOURCE MANUAL DATE 6-4-88 Field Notice 76 Issued 4-20-88 ADVICE: 621-9937 PIOM Approximately 200 621-9937 PIOM’s have been shipped over an extended period of time with a defective socket. We can not determine where these PIOMs may have been shipped. This socket, which is used with the gate array, has been reported to allow the gate array to back out resulting in a loss of or intermittent connections to the gate array, The most noticeable affect of this condition is the loss of communication to certain card slot(s) located in the rack with the affected PIOM. The only way to identify suspected PIOMs is to visually inspect the gate array socket on the PIOM which is located close to the card edge connector and can be viewed from the rear of the module. It is not necessary to remove the module cover. Defective sockets can be identified by color; black sockets are defective, brown sockets are correct. As a remedial measure a PIOM that has a black socket and is exhibiting the described problems could be corrected by applying pressure to the gate array thus reseating it in the socket. As a permanent solution all 621-9937 PIOM’s with black sockets must be replaced. This will be accomplished by an exchange program. Customers with affected PIOMs can obtain replacement 621-9937 PIOMs by contacting Ann Sherron at Honeywell IPCO York, PA. Please be prepared to enter a purchase order for the required quantity of 621-9937 PIOMs. Upon receipt of the PIOMs return the defective PIOMs to York for full credit. A returned goods authorization (RGA) must be obtained from Ann Sherron prior to returning the defective PIOMs. oneywel Industrial Automation Systens Division Honeywell Industrial Services DivisionTDC 3000 TAB Pp is CUSTOMER . PAGE ___B04 (B) RESOURCE MANUAL DATE 1-30-92 620 Les FIELD BULLETIN 11/25/91 621-9937/9930 PIOM and 621-9929 Parallel Bus Selector PROBLEM CAUSE RECOVERY ASCI 1/0 Power Up Condition A situation can occur when powering up a 620 processor system configured with multiple parallel 1/0 racks. The symptom will only occur during power up when power is sequenced to the processor and then individually to each I/o rack. The loader will indicate that some inputs in the second rack and beyond are energized or toggling when in fact they are de-energized in the field. This situation will not occur if power is applied to the entire system at one time. The symptom occurs because the DC power from the processor or first I/O rack is fed through the parallel 1/0 cables to the succeeding I/0 racks. The voltage is too low to allow the ASIC chip on particular input modules to power up in a proper operating mode. When AC power is applied to the I/O rack, the ASIC chip continues to operate in a diagnostic mode. Input modules incorporating this ASIC device are: 621-1160, 621-1180, 621- 3560, 621-3580, 621-1250 and 621-1251. The quickest way to clear this situation is to remove power from the entire system (processor and 1/0) and reapply power to the entire system at one time. Once the system is powered and operational, an individual rack can be powered down without causing the situation to reoccur. Continued on next page Honeywell Industrial Autenstion and contratTAB _PD 18 BO4 (B PAGE _2_ DATE _1-30-92 621-9937/9930 PIOM and 621-9929 Parallel Bus Selector ASCI I/0 Power Up Condition, Continued FIX Honeywell has engineered changes to the 621-9937 and 621-9930 PIOM modules and to the 621-9929 PBS module which will prevent the low voltage from being fed from PIOM to PIOM through the parallel 1/0 cable. CORRECTIVE Should you experience this condition and feel it ACTION is necessary to have your PIOM and PBS modules updated, you may contact Honeywell to request an exchange of your'modules. Please have a no charge purchase order number available at the time of your call. IDENTIFICATION Modified 621-9937 and 621-9930 modules will be identified with a HRO1 label. Modified 621-9929 PBS modules will be identified with a HRO2 label. Honeywell Industrial Automation and ControtTDC 3000 TAB PD 18 CUSTOMER PAGE BOS _(A) RESOURCE MANUAL DATE Field Notice 93 & 93-A Issue Date 11-88 ITEM: Serial I/O system (SLM 621-9936, SIOM 621-9935) BACKGROUND: An upgrade to the former 620 serial I/O system has been ACTION: NOTE: made. This upgrade effectively reduces the number of serial link faults experienced by a 620 serial 1/0 system due to electrical noise. with SLM Revision J firmware and SIOM Revision D firmware (or older serial 1/0 firmware) CRC errors introduced by electrical noise would cause a serial link fault. With SIM Revision K firmware and SIOM Revision E firmware, the tolerance for this type of error has been increased by requiring the system to retry communicating the message affected by the noise up to eight times before declaring an error. The upgrade kits for the SIM and the SIOM have different part numbers and must be ordered separately. The quantity of each kit needed will depend on how many of each module needs the upgrade. Each kit contains one set of firmware. They will be available in December, 1988 at no charge to the user. The part number for the SLM (621-9936) Upgrade kit is 221-0005 with rev k firmware. The part number for the SIOM (621-9935) Upgrade kit is 221-0004 with rev E firmware. If the SIM is upgraded, all SIOM,s connected must also be upgraded for this fix to be effective. Honeywel Industrial Automat on Systems Division Honeywell Industrial Services DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE BOS _(B! RESOURCE MANUAL DATE 5-289. Field Notice 99 Issued 3-20-89 ITEM: 621-9938 Dual Port Serial 1/0 Module BACKGROUND: The 621-9938 is the dual channel SIOM which resides at a remote I/0 rack. Two channels are provided on the 621-9938 to support redundant communication to the SIOM (I/O rack) from redundant 620 processors. A potential problem has b discovered with the 621-9938 module which may exist under certain conditions. Due to component tolerances this problem does not exist in all modules. However, since there is no vay to determine which modules may have more sensitive components this problem is being Field Noticed to alert you to this potential problem. This problem is exhibited only on those modules which were shipped from York prior to February 1, 1989. The problem with the 621-9938 only exists when the module is used with redundant 620 processors and when processor B has been powered down or communications on channel B has stopped. Under these conditions, with channel A configured to recognize faults and shutdown on a fault, it is possible for communications on channel A to be coupled onto channel B and fault the SIOM which shuts down the affected SIOM and, because the A channel is set to recognize faults, results in shutting down the entire A channel. Note, when a serial 1/0 channel is configured to recognize faults and shutdown, a switchover from the lead to the backup processor can be made on a serial communication fault. If channel A is configured to ignore faults and maintain operation it is still possible for communications on channel A to couple onto channel B (when channel B is shutdown). If this occurs the effected SIOM would shutdown but because the channel is configured to ignore faults the channel would continue to operate. It is also possible under these conditions when the effected SIOM shuts down that the SIOM fails with its transmitter stuck on which jams the link. The channel would still continue to try and operate under these conditions but could not until the failed SIOM with the stuck transmitter is shutdown. Moneywel Industrial Automation Systens Division Noneywel Industrial Services DivisionTAB _PD 18 BOS (BI PAGE _2_ DATE _5-2-89 _ Communications from channel A can only be coupled onto channel B when channel B is shutdown either by powering down processor B or by a channel failure. If channel B ceases to communicate for any reason other than the processor is powered down, the state of the channel can be determined by the following: © Active LED for the channel on the SLM will be off. © The Input/PULL Data Ready Bit from the Serial I/O Status Table for the effected channel will be off. © Also from the Serial 1/0 Status Table the number of SIOMs On Line Register for the effected channel will read 0. With the previously described conditions it is possible for communications on channel A to be coupled onto channel B due to the close proximity of the channel A transmitter transformer to the channel B receiver transformer on the SIOM printed circuit board. Also the channel B receiver transformer must be sensitive enough to pick up communications from channel A. Due to component tolerances some channel B receiver's circuitry can be sensitive enough to be effected under the described conditions. Listed below are the possible redundant configurations and the possible failure scenarios. case I Channel A of the 621-9938 is connected to the lead processor and configured to recognize faults and shutdown on a fault. Channel B is connected to the backup processor and is configured to ignore faults and maintain operation. If the B processor (backup processor) is powered down or channel B communications is shutdown it is possible in sone cases for communication on the A channel to be coupled over onto the 3 channel and cause a fault which shuts down the effected SIOM and, because the A channel is set to recognize faults, results in shutting down the entire A channel. If for this same configuration channel A is powered down or channel A communications is shutdown switchover will occur to channel B. For this condition there is no possibility of communications on channel B being coupled onto channel A and the system will operate as specified. Honeywell Industrial Autenation Systems Division Honeywell Industrial Services DivisionTAB _PD 18 BOS (B. DATE _5-2-89 _ CASE IT With the previous configuration reversed, channel B connected to the lead processor and configured to recognize faults and shutdown, and channel A configured to ignore faults, powering down processor B or if communications on channel B is shutdown, switchover to processor A and serial communications like A would take place. Channel A could possibly still couple over onto channel B shutting down the rack where the problem occurred. As described previously. it is also possible with this type of failure for the SIOM which failed to have its transmitter failed on, since channel A had been configured to ignore faults, the channel would attempt to remain operational. With the above configuration if channel A is powered down or communications on channel A is shutdown, communication will continue on channel B, again there is no possibility of communications on channel B being coupled onto channel A, and the system will continue to operate as specified. CASE IIT Channels A and B are configured to shutdown on a fault, processor A is the lead processor with B as the backup processor. If processor B is Powered down or communications on channel B is shutdown, channel A could couple onto channel B reaulting in the SIOM faulting and chutting down channel A. With the same configuration, if processor A is powered down or communications is shutdown on channel A, switchover would take place to channel B and communication would continue on channel B. Again there is no possibility of communications on channel B being coupled onto channel A and the system will continue to operate as specified. Channels A and B are configured to ignore faults, processor A is the lead processor with B as the backup. If processor B is powered down or communications on channel B is shutdown, channel A could couple onto channel B resulting in the SIOM faulting and shutting down. The SIOM could also fail with its transmitter stuck on locking up the link as the Link would continue to try and operate since it was configured to ignore faults. With the same configuration, if processor A is powered down or communications on channel A is shutdown, switchover would take place to channel B and communication would continue on channel B. Again there is no possibility of communications on channel B being coupled onto chennel A and the system will continue to operate as specified. Honeywell Industrial Automation Systems Division Honeywell Industrial Services DiviTAB _PD 18 BOS (B) PAGE _4_ DATE RECOMMENDATIONS : Under normal operation when both channels A and B are powered up and operating this problem does not exist. A problem potentially only exists if the 621-9938 is connected to redundant processors and channel B is powered down or communications on channel B is shutdown. This problem does not occur on all 621-9938 modules due to component tolerances. Also this problem will NOT occur for 621-9938 modules which are used in non-redundant configurations. If channel B must be powered down it is possible to first remove the channel B connector from each SIOM before powering down the B processor. This precaution will eliminate the described problem until the 621-9938 module can be modified. PROBLEM RESOLUTION: Upgrade Kit No. 228-0002 may be ordered to correct this potential problem. The upgrade kit will be available at no charge for a period of 6 months, until October 1, 1989. After October 1, 1989 the upgrade kit will have a list priceof $100.00. This kit contains 4 capacitors and an instruction sheet. The modifications required are removing 4 capacitors and replacing them with the 4 contained in the upgrade kit. This modification should only be made by a qualified Honeywell service Person. This change has been made to all modules in stock. Any 621- 9938 module shipped from York after February 1, 1989 incorporates this modification and is not effected by this Field Notice. For most redundant applications plant shutdowns are infrequent and scheduled for a minimum downtime. To better accommodate these plant shutdowns Honeywell York can also upgrade any 621-9938 module through a customer exchange program, in lieu of the upgradé kit. For applications which have scheduled shutdowns this exchange program may help minimize downtime. Please contact Pat McGuigan, of Customer Service (717) 848- 1151 x411, as far in advance of a plant shutdown as possible to schedule and make arrangements for the exchange program. This will help us to plan appropriately to meet your plant requirements. For this exchange program to be successful once the exchange is made the return unit must be returned within 5 working days. Pat McGuigan will provide the Return Goods Authorization number for these return units. Similarly to the upgrade kit this exchange program will be available at no charge for a period of 6 months, until October 1, 1989. An exchange which has been brought to Honeywell's Customer Service attention within this time period, but which may not be scheduled to be implemented until after October 1, 1989 will still be honored at no charge. After October 1, 1989, the normal repair and exchange program will apply at the regular exchange price Honeywell Industrial Automation Systens Division Honeywell Industrial Services DivisionTDC 3000 ‘TAB PD 18 CUSTOMER PAGE BOS (Cc) RESOURCE MANUAL DATE 5-2-89 Field Notice 100 Issued 3-23-89 ITEM: 621-9939 SLM / 620-16 COMPATIBILITY WARNING WARNING = WARNING -- WARNING -- WARNING -- WARNING _-- WARNING ~~ WARNING = WARNING -- WARNING -- WARNING -- WARNING -- WARNING -- WARNING BACKGROUND: The 621-9939 SIM (Rev. 1.9) is not to be used with ACTION: the new 620-1631 processor. Any 620-16 system using an SIM manufactured before January 10, 1989 will exhibit uncontrolled serial 1/0 operation. Incompatible existing stock or spare part inventories are identified by the Version.Revision number shown on the outside of the 621-9939 container, "1.9". These modules should be pulled from these inventories and upgraded as soon as possible using the 221-0012 upgrade kit available immediately. Because this change to the SIM is hardware-only, and does not involve a firmware or software revision, the Version.Revision number on the module will remain at "1.9", In the future, the only way to identify compatible 621-9939 modules will be by the Assembly Level tag fixed to the top of the circuit board during manufacturing or by a second label (with the number 221-0012 printed on it) attached to the bottom of the board when the upgrade kit is installed. SLMs with an Assembly Level of G and above will be compatible with the 620-16 processor family. Upgrade kits for the 621-9939 SLM may be ordered through the Customer Service Dept. in York, PA at 717-848-1151. The kits will be free of charge through July 30, 1989. Noneywel Industrial Automation Systems Division Honeywell Industrial Services DivisionTDC 3000 TAB Pp 18 CUSTOMER PAGE BO5_(D) RESOURCE MANUAL DATE 12-18-89 Field Notice 112 Issued 9-11-89 ITEM: 621-0096 Serial I/0 Module (SIOM) The 621-0096 SIOM used with the IPC 96 I/O cardrack system is designed for use with 621-9939 Serial Link Module (SLM) firmware 2.0. When used with SIM firmware 1.9, two aspects of system performance should be taken into consideration as follows: 1 If a 96 1/0 drop has a starting address that exceeds 2039, the drop will be logged into the SIM’s data table as being a valid, ON LINE drop upon system generation. The addresses 2040-2047 are reserved for use by the Enhanced Diagnostics incorporated into SIM firmware 2.0 and therefore, should not be used as starting addresses IN_ANY_SYSTEM CONFIGURATION. If a 96 1/0 drop has gone OFF LINE, it is possible for the SLM (firmware 1.9) to indicate in the status table that it is still on line. Additionally, two other points are worth mentioning in this field notice as follows: 1. The 621-0096 SIOM can have a starting address in increments of eight, but SEND OUTS in a 621 serial system must be addressed on 16 point (real 1/0) boundaries. The 621-0096 SIOM cable connector is orientated 180 degrees opposite of the 621 serial cable connector. 621 serial cables must be rewired to be used with the 621- 0096 SIOM. Woneywell Industrial Automation and Control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE BOS (BE) RESOURCE MANUAL DATE 9-28-90 FIELD NOTICE: #127 Issued 4-3-90 ITEM: 621-9938-/9939/9940 Serial I/o Firmware V.R 2.1 A number of changes have been made to the firmware of the 621-9938 and 621-9940 Serial 1/0 Modules (SIOMS) and the 621-9939 Serial Link Module (SLM). These changes correct several product problems, provide improved error detection, indication, and recovery mechanisms, and provide several enhancements. Details of all changes made are provided below 1, ERROR DETECTION AND RECOVERY a. Transmitter Underrun Detection at the SLM Additional run-time diagnostics have been incorporated into the 621-9939 SLM to allow for the detection of transmitter underrun. Transmitter underrun is a condition which occurs when the Advanced Data Link Controller (ADLC) on the SLM stops receiving characters in the middle of a message. Transmitter underrun is considered a serious hardware problem with potential to affect both channels; thus, upon detection of this error, the SLM will post an error code in its status registers (see item 3 below) and shut down both channels. A hardware RESET or a power cycle is then required to restart the unit, to ensure that the unit performs its hardware self-test before attempting to control 1/0 again. b. Message Length Checks at the SIOM V.R 2.1 of the 621-9938 and 9940 SIOM firmware now allow checking of the length of received messages versus expected length. This checking, together with the CRC-16 checking performed in all revisions, increases overall message data security. 2. UNCONDITIONAL LINK SHUTDOWN PROCEDURES Several changes have been made to the procedure which the SLM uses to determine whether or not a channel fault will result in an unconditional link shutdown. An unconditional link shutdown is defined as complete termination of communications on a serial link, without regards to the DIP switches on the SIM which determine link shutdown response. Noneywel\ Industrial Automation and Control DivisionTAB _PD 18 BOS (E: PAGE _2_ DATE _9-23-90 All SIOMs Going Off-Line During Switchover In previous versions of the SLM, if all STOMs on a link went off-Line during a power-up, restart, or redundant switchover, the channel would experience an unconditional shutdown. Shutdowns of this type would typically occur in a redundant system if all SIOMs on a link were powered down simultaneously. Recovery would then require power-up of the affected SIOMs and a restart of the SIM. In V.R 2.1 of the SLM, the unconditional shutdown response is no longer used in this situation. b Transmitter Underrun The detection of a transmitter underrun condition, described in 1 above, will now result in an unconditional shutdown of both links on the affected SLM. DIAGNOSTIC CODES FOR LINK SHUTDOWNS V.R 2.1 of the SIM firmware provides the user with better diagnostic information in the case of unconditional link shutdowns. Error codes, which are pre-defined values that fall outside of normal I/O range, will be posted in the "Starting Address of SIOM Off-Line” register (2041-2045) for the affected channel when an unconditional link shutdown occurs. The possible codes (in DECIMAL) are: 10,000 - Excessive Retries (occurs if SLM must retransmit too many messages in a single link scan.) 20,000 - Transmitter Underrun - see 1A above (requires RESET or power cycle to recover; posted in address for both channels.) 30,000 - Channel Shutdown by Other Channel (occurs if Shutdown Response for other channel was “Both Channels Cease Operation or Shutdown All I/O" and a fault occurred on the other channel.) SOFTWARE RESTART OF SERIAL LINKS With V.R 2.1 firmware, the SLM can now be restarted by PUSHing a value to SIM status register 2041 (SIM Restart Command Register). PUSHing the appropriate value to this location will have the same effect as shorting the RESTART terminals on the SIM; that is, any SIOMs hich were taken off-line by the SLM will be retried, and communications will be restored on any channel which had shutdown. ‘The PUSH may be performed by the user's ladder logic, or may be done through an option module, such as the HIM. If programmed in ladder logic, the PUSH should be one-shot, unless a continuously restarting action is desired (note that this would defeat much of the diagnostics available). If the HIM is used, the user should configure a Timer/Counter point on the Hiway with a PLC address of 2041. Woneywel Industrial Automation and Control DivisionTAB _PD 18 BOS (E PAGE DATE The values to PUSH to this location are: 1. Restart SLM #1 2. Restart SLM #2 3. Restart BOTH SIMs SLM 1 & 2 are differentiated by SW6 on the SLM (OFF for #1, ON for #2). The SLM will automatically reset the value to zero; there is no need for the user to PUSH zero to the register. It should be noted that this feature will not function in the PROGRAM, DISABLE, or I/O Power Fail (P/F) modes, because PUSHes to 1/0 are not allowed in these modes. ‘LINK FAULT LED In V.R 2.0 of the SIM firmware, under certain circumstances, it was possible for the Link Fault LED to remain OFF when a link fault occurred. This would happen on links set to shut down both channels after the link had shut down and been restarted via the RESTART contacts. The Link Fault LED would not turn on if a second link fault occurred. This problem has been corrected in V.R 2.1. LEADERSHIP CONFLICT RESOLUTION AT SIOM When severe communications problems exist (for example, RCV + shorted to shield), it is possible for only a small percentage of messages to get through’to a S1OM. Hach message has associated with it a single bit which the SIOM uses to determine which processor is in the Lead. Every SIOM on the link looks at this bit in every message, whether or not the message is addressed for that particular SIOM. With a severe communications problem occurring on "A", it may be possible for a SIOM to receive a message addressed for a different SIOM and to make its "A" port the Lead. If, however, all messages addressed to that SIOM fail, the port never begins exchanging I/O data with the SLM, and hence does not come fully on-line. If a switchover then occurs (presumably due to the serial link problem), the "A" port does not receive a message telling it that it should be the backup, The "B” port is, however, receiving messages which tell it to take the Lead. Thus, a Lead Conflict situation can occur at the SIOM. In previous revisions SIOM firmware, this conflict would have been resolved in favor of the partially-active "A" port, and a link fault would have been generated on "B". Changes made in V.R'2.1 now cause the preference to be given to a fully on-line port instead of a partially on-line SIOM port. 32-PT. PUSH/PULL CARDS Changes made to the SIOM and SLM firmware allow for the possibility of up to 12 32-PT PUSH/PULL cards in a SIOM rack. V.R 2.0 placed a restriction of ten 32-PT cards and a further limitation of only 32 additional digital points in a single rack. With V.R 2.1, the user can now use 12 32-PT "SMART" PUSH/PULL cards which employ the paging feature in a single serial rack. It should be noted that the user should still NOT place 4-PT or 8-PT FUSH/PULL cards in 32-PT slots in the serial 1/0 system, but should use only 8-PT slots for these cards. Honeywell Industrial Automation and Control DivisfonTAB _PD 18 BOS (E PAGE _4_ DATE _9-23-90 _ 10. ‘"B" PORT SHUTDOWNS A problem in previous versions of the SIOM created the possibility that, under certain link timing conditions, the "B” port on the SIOM with the most significant address on a link vould go off-line. The problem was caused by the fact that the SIOM always served the "A" port first, and hence did not always get to the “B" port quickly enough. Changes made to the SIOM firmware now cause priority to alternate between the “A” and "BY ports, and hence correct the problem. ALL STOMs ACTIVE ON REDUNDANT LINK If the "B" processor powers up SLIGHTLY before the "A", and an “A-to-B" switchover occurs BEFORE the links have finished being configured, the All SIOMs Active On Redundant Link status bits on the "B" processor would not indicate the active state. This problem, which existed in all Previous revs., was corrected in V.R 2.1 of the SLM. DATA “BUMPS” DURING SWITCHOVER ‘Three problems were found which could cause improper 1/0 data during a redundant switchover. Please note that these problems would ONLY occur at switchover, and NOT during normal operation. All of these problems were corrected in V.R 2.1. a. Outputs Next to EDM A problem introduced in SLM V.R 2.0 would cause data gathered from the EDM in slot "A" pf a rack to be sent to slot “BY of the rack during redundant switchover. The problem would clear itself as soon as the program wrote new data to the SLM. The problem is fixed in V.R 2.1, by writing the data to the correct card slot. b. Outputs Above Address 1023 A discrepancy present since SIM V.R 1.9 would cause data from outputs above address 1023 to be stored to an incorrect location in RAN during data gathering at redundant switchover. The SLM would then look at the RIGHT location when updating outputs to addresses above 1023 during the switchover. If the outputs in the report were controlled by 1/0 PULL data, which is not transferred in the Redundancy Database, then the correct location would not be updated correctly by the user program, and the data used to update the I/0 will be either zero or the data present when the SIM was last in the Lead. The outputs would then be overwritten with correct data when they were updated by the user program after PULL data was ready (after the switchover is complete). This problem was corrected in V.R 2.1 by writing the data gathered from the outputs to the correct RAM locations. Please note that this problem ONLY occurred in outputs above 1023 which were directly controlled by PULL data from the 1/0 Honeywell Industrial Automation and Control DivisionTAB _PD 18 BOS (E) PAGE DATE _9-23-90 _ ¢. PULL DATA DURING SWITCHOVER All previous revisions of the serial firmware contain a bug which could cause the Input/PULL Data Ready (IPDR) Bits to be set before all PULL data had been updated after a switchover. During a switchover, the IPDR bits are cleared by the SIM until the new leader has completed a serial link scan and gathered data from all inputs and PULL cards. The clearing of these bits causes the user progran to “short scan” to prevent it from updating 1/0 based on old data, If the SLM was set to service one PUSH/PULL card per rack per scan (SIM SW5 ON), though, the SLM would collect all digital data but only PUSH/PULL data from a single card in each rack before turning the IPDR bits on. This could have resulted in the use of PULL data from the last time the unit was in the lead, or zero data, until the SLM had completed enough scans to service all PUSH/PULL cards in the system. ‘The problem has been corrected in V.R 2.1 of the SLM firmvare. d. Improper EDM Trigger In V.R 2.0, a problem existed which would cause an 621-0021 EDM in cardslot "A" of a rack with Rack Fault and outputs frozen to trigger momentarily during a redundant switchover. The problem was caused by an error in the “Keep-alive” function, which should keep an EDM energized during switchover. A change in V.R 2.1 of the SIOM vill Prevent the "Keep-alive" function from triggering the EDM if a rack fault exists. 11, DMA HANG-UP HARDWARE PROBLEM In early versions of the SLM and SIOM hardware, the potential for a hardware lock-up existed when the devices were connected to inappropriate communications channels. The problem would occur when message reception started at the Advanced Data Link Controller (ADLC) on the SIM or SIOM board. The ADLC would signal to the Direct Memory Access Controller (DMAC) that it needed to have characters read from it. The DMAC would then request the use of the data bus from the microprocessor by asserting its HALT line. The microprocessor would then signal back to the DMAC that the bus was available by asserting its Bus Grant Line. If an error was detected by the ADLC AFTER the ADLC had requested service, but BEFORE the microprocessor had asserted Bus Grant, the DMAC would hold the HALT line asserted indefinitely. This situation, known as DMA Hang-up, would cause the SIOM or SIM affected to stop running completely. Symptoms of the problem include a SIOM ACTV LED which is ON all the time (NOT Flashing), or an SLM which drops links without ANY indication (NO FAULT LED, PASS LED ON, ACTV LEDs ON, and no change in serial status registers). As stated previously, problems of this type have ONLY been seen where inappropriate communications channels were used; the two instances of documented problems involved the use of a fiber optic modem which could not handle the system's baud rate, and the other involved the use of improper cable. Honeywell Industrial Automation and control DivisionTAB _PD 18 BOS (E) PAGE _6_ DATE _9-23-90 The potential for the problem has been removed from all new boards, however, these changes cannot be revorked onto older units. If a customer believes he is experiencing a DMA Hang-up problem, they should contact the Technical Assistance Center in York at (717) 771-8180 to arrange an exchange of modules, and to discuss other possible communications problems. The customer should be prepared to provide failure symptoms and the serial number of the suspect board. RETROFIT RECOMMENDATIONS Because V.R 2.1 of the serial 1/0 system represents a significant improvement over the older versions, it is strongly recommended that users update their systems with a new version as soon as practical. Users of redundant and Hivay-connected systems should consider updating their 620-0059 ROMs (see F/N #126) and 620-0081 HIMs (see F/N #125) to V.R 2.2 and V.R 2.1 respectively at the same time. Since the hardware problem described in this Field Notice only occurs in improper installations, no retrofit is needed for the vast majority of users. As mentioned previously, users who feel they are experiencing this type of problem should contact TAC in York. UPGRADE KIT INFORMATION V.R 2.1 of thé Serial I/O System contains all of the firmvare enhancements and changes described above. Upgrade kits for the 621-9938 and 621-9940 Serial 1/0 Modules are 221-9938-2 and 221-9940-2, V.R 2.1, respectively; the upgrade kit for the 621-9939 Serial Link Module is 221-9939-2. Orders are now being accepted for these upgrade kits, which will be available after May 14, 1990. The kits will be available at no charge until August 14, 1990, when a $100 list price will apply to each of the kits. Honeywell Inehustrial Automation and Control DivisionTDC 3000 TAB PD18 CUSTOMER PAGE BOS (F) RESOURCE MANUAL DATE 9-28-90 FIELD NOTICE: #133 Issued 8-24-90 ITEM: Serial Input/output Modules 621-9938 and 621-9940 ‘BACKGROUND: A situation occurs where the SIOM will receive erroneous count values from intelligent I/O modules that utilize PUSH/PULL interface through Honeywell's Application Specific Integrated Circuit (ASIC). The Problem occurs because the ASIC causes a ground bounce on the serial 1/0 backplane. The modules affected by this phenomenon are the 621-0019 Pulse Quadrature Input Module and the 621-0020 Universal analog Input Module. NOTE: THIS PROBLEM ONLY OCCURS WITH INTELLIGENT 1/0 MODULES ‘THAT UTILIZE PUSH/PULL INTERFACE THROUGH THE ASIC IN SERIAL I/O. NO OTHER MODULES ARE AFFECTED BY THIS PROBLEM. FIX: This problem is corrected by adjusting the serial 1/0 backplane timing. ‘The rework involved requires a soldered component to be replaced. Due to the nature of this repair, all rework will be done by York Manufacturing, therefore, the SIOMs must be sent to York for rework. ‘The indication that this rework has been completed on the STOMs will be @ label "HRO1" (Hardware Revision 01) attached to the front coverplate of the stom. REWORK INFORMATION: The rework for the affected sIoMs can be scheduled by contacting Pat McGuigan of York Order Entry with a Return Goods Authorization Number at (717) 771-8111 between the hours of 8:00 a.m. and 5:00 p.m. Eastern time. There will be no charge for this rework. Moneywell Industrial Autonation and control DivisionTDC 3000 TAB PD 18 CUSTOMER PAGE __B05 'G) RESOURCE MANUAL DATE __7-1-92 FN: 149 FN date: 6-1-92 621-9939 SERIAL LINK MODULE (SLM) - OUTPUT CARD FAULT ADDRESS Background Action Upgrade Kit In VO rack configurations where zero point /O modules have been assigned, Card Fault addresses will toggle on/off in the system status table of the Logic controller (addresses 2416-2431) if a card fault occurs. Also, the Card Fault Count registers of the system status table will toggle at the same time (addresses 2414-2415). All versions of 621-9939 SLM firmware prior to V.R 2.2 may exhibit this problem. A special flag has been added to skip card fault processing on zero point I/O slots in V.R 2.2. This SLM version is fully compatible with all previous SIOM firmware releases. This upgrade is recommended but not mandatory as it affects the diagnostics operation of the SLM and does not affect system operation. V.R 2.2 firmware upgrade kits will be available free of charge until ‘September 15, 1992 by contacting the Honeywell Customer Service Center and ordering part number 221-9939-2. Orders placed after that date will be subject to a $100.00 charge per upgrade kit.TDC 3000 TAB pp 18 CUSTOMER PAGE __B05 iq) RESOURCE MANUAL DATE __8-26-92 FN: 150 FN dete 8-4-92 LCS 620 Serial /O Modules Model Numbers Affected Problem Solution Availability 621-9988 V.R 2.x or lower 621-9940 V.R 2.x or lower 621-9938R V.R 3.0 or lower 1. In systems using 621-9938 or 621-9940 SIOMs: If the 621-9939 module (SLM) is configured to update one push-pull ‘ard per lO rack per scan and if any of the SIOMs have been shut down due to the action of an EDM (Enhanced Diagnostic Module), then the pull data received by the SLM is invalid for racks with more than one push-pull card. 2. In systems using the 621-9938R The situation is the same as above but can also ocour if the 621-9938R ‘SIOM has the Backplane Disable switch in the freeze position. 3. Redundant systems These systems have the same problems as above but are also affected if the switchover from lead to backup occurs while the /O backplane is shutdown. The new lead processor will be updated with incorrect information from the SIOM. V.R 3.1 firmware will correct the problem by maintaining a record of all pull data and it will use this database to respond to the SLM while the backplane is disabled. The fix affects all models of the SIOM and it will be downward compatible with all SLMs. Part numbers 221-9938-3, 221-9938R and 221-9940-3 can be ordered from your local Honeywell office. The following information will be required at the time of your call: 1. Valid purchase order number. 2. Serial number of each product being upgraded. 3. Customer's company name, customer contact name, phone number, and location where product is to be shipped. oneyweli Industrial Automation and contro}TDC 3000 TAB PD 28 CUSTOMER PAGE __B05 iT RESOURCE MANUAL DATE __9-9-92 FALSE "POWER FAIL" SIGNAL ON POWER UP OF SLM (621-9939) Ver. HRO1 Background Actions Factory Exchange On power up, the SLMs with hardware version HRO1, may cause a false Power Fail signal to occur. While the Power Fail Signal is true, the Processor Module will not enter the Run mode regardless of the key switch position. If either Parallel or Serial I/O is attached, all Paralle! I/O Modules or Serial /O Modules will clear or freeze /O based on their DIP switch settings. The Loader status display (bottom line of display when monitoring Ladder Logic) will indicate "P/F" in the Mode field. The signal will return to normal over a period of up to five (6) minutes. After the necessary time has elapsed, the Processor will enter the Run mode if the key switch is placed in the Run or Run/Prgm Positions. No other symptom of the problem has been observed, but it may re-occur if the Processor is without power for more than a few minutes. Because this problem is affected by component tolerances in associated modules such as the 620-0088 PLDM and 621-9937 PIOM, not all HRO1 SLMs will exhibit this problem. If the problem is observed or the customer desires to prevent the possibility of this problem occurring in the future, follow one of the two Actions described below. If the SLM does not have the HRO1 identification (on the front panel), it does not require modification. A SLM Ver. HRO1 can be on site-modified or factory exchanged. THIS ON-SITE MODIFICATION MAY BE ACCOMPLISHED IN THE FIELD BY AUTHORIZED HONEYWELL PERSONNEL ONLY. If desired, a replacement SLM with the modification installed and identified as HRO2, can be requested by calling your local Honeywell office. Continued on next page Honeywell Tedustria} Autonation and ControlTAB _PD 18 BOS (7 PAGE _2 DATE __9-9-92 FALSE "POWER FAIL" SIGNAL ON POWER UP OF SLM (621-9939) Ver. HRO1, Continued Factory Exchange, Continued On-Site Modification Please have a serial number for each module to be exchanged and a purchase order number available before requesting the exchange. Exchanges will be performed at no charge to the customer until January 1, 1993. If you must schedule the exchange around a plant shutdown, contact your local Honeywell office with quantity of SLMs to be exchanged and desired delivery dates. Modules not scheduled for exchange by Jan. 1, 1993 may be exchanged at the Module Exchange Price in effect at that time. The problem can be permanently solved by performing the modification shown in the accompanying instructions. See diagram on following page for jumper location. IMPORTANT!!! Remove power from 620 LCS Processor Rack before removing or installing 621-9939 Serial Link Module. 4. When performing this modification Electro-Static Discharge precautions must be followed. All work should be performed ata certified ESD work station. 2. Remove module component cover. 3. Cut a3 inch (7.62 cm) piece of 30 gage (0.255 mm diameter) insulated wire. 4, Refer to attached circuit board drawing for wire routing. This modification should be performed on the component side of the module, 5. Attach one end of wire to pin 14 of RN1 and solder in place. 6. Attach other end of wire to C18. Wrap wire around leg of capacitor that enters circuit board feed-through hole, and solder in place. 7. Check for solder shorts between RN1 pins and between the C18 connection and other circuit runs or components. ‘Continued on next pageTAB _pD 18 BO a PAGE DATE __9-9-92 FALSE "POWER FAIL" SIGNAL ON POWER UP OF SLM (621-9939) Ver. HRO1, Continued On-Site Modification, Continued Reference diagram at bottom of page. 8. 9. 10. 11. Remove excess flux with appropriate flux cleaner. Using a fine point permanent marker change HRO1 label on the front plate of the module to read HRO2. Install component cover on module. The module is now ready to be installed in the processor rack. Perform the following test to ensure correct module operation: ‘A. Install 621-9939 in processor rack. B. Attach Loader to 620 LCS processor, keyswitch to "PRGM" mode. C. Power up processor, verify 621-9939 "Pass" LED comes on D. Verify that Loader status line does not indicate "P/F" in Mode field. E. Turn keyswitch to "Run" mode, verify processor goes to run mode. Jumper wire to ada v8 SLM 621-9939 3S 136TDC 3000 TAB pp 18 CUSTOMER PAGE _BOS (J) _ RESOURCE MANUAL DATE __12-23-92 FB:20 FB Date :11-6-92 SERIAL I/O MODULES 621-9938, 621-9938R & 621-9940 Background Action Honeywell has determined that particular configurations of 621 serial /]O may experience link faults, due to signal reflections created on the communication link. Signal reflections are caused by the combination of cable length, cable type, placement of /O racks in clusters along the cable and the individual capacitance added to the link by each Serial /O module. Itis not uncommon for a serial communication link to have some amount of reflections; however, should the amplitude be excessive and the timing of the reflection occur on the rising edge of the signal, a link fault might result. To date, Honeywell TAG is aware of only one instance in the field where the serial /O link configuration produced reflections on the /O link responsible for causing link faults. See Figure 2 for a diagram of that system. ‘Steps can be taken to plan the configuration and layout of the serial /O links which can prevent or reduce the level of signal reflections. They are: 1) Avoid creating clusters of /O racks along a link by connecting local racks to one serial link channel and connecting remote racks to a second serial channel. Limiting the number of racks on a serial channel will also increase the data throughput of the link. 2) Use the recommended cable for the distances required. Honeywell recommends Belden 9729 cable for distances up to 4000 feet and Belden 9182 cable for distances over 4000 feet and up to 10,000 feet. Although the probability is very low for a particular link configuration to produce these results, Honeywell has made changes to the 621-9938, 621- 9938R and 621-3940 serial I/O modules to reduce the potential for signal reflections on the serial /O link. A capacitor has been removed irom the SIOM modules to eliminate or greatly reduce the amplitude of reflected signals. With the removal of this capacitor, Honeywell will no lorger be able to support trunk line drop configurations; all serial links will have to be wired in a daisy chain configuration. See Figure 1. On redundant SIOMs, this capacitor also aided in preventing cross talk between the A and B ports of the SIOM. Therefore, it was also necessary to upgrade the firmware to insure that any messages coupled into the B port of the redundant SIOMs are rejected and are not interpreted as valid messages from the SLM. ‘Continued on next page Hoeywell industrial Automation and CostrotTAB _PD 18 B05 (J) PAGE _2_ DATE __12-23- SERIAL I/O MODULES 621-9938, 621-9938R & 621-9940, Continued Action, Continued Modified 621-9938 R modules will be labeled with an HRO1 indication. Modified 621-9938 modules will be identified by an HRO2 label and 621- 9940 modules will have an HR0S label. The new firmware will be version 3.2. Serial link faults may be caused by factors not associated with this notice. Customers experiencing serial link faults are urged to discuss this matter with your local Honeywell Technical Assistance Center (TAC). Based on that discussion, the TAC engineer may recommend upgrading you serial I/O modules. Daisy Chain Trunk Trunk with Drops Configuration Configuration 621-1/0 621-0 621-0 621-0 H This trunk with drops configuration is not supported with the modified SIOM hardware. Figure 1 Continued on next page Moeaywell Industriel Rutenation and controlTAB _PD 18 B05 (J) PAGE _3_ DATE __12-23-92 SERIAL I/O MODULES 621-9938, 621-9938R & 621-9940, Continued Failure Example The following diagram is of the system that experienced link faults due to signal reflections. R Ke Cc) 620-35 ' 621-10 3 M k R k 4 620-35 621-1/0 4 t |_| Ke ke 621-10 1 621-10 5 iG kK 621-1/0 2 k 621-110 6 KA Local Racks k Notes: 621-10 7 k 1. Total cable distance between processors and rack 2 is 10 feet. 2. Cable length betw. ks : Zand 3is 150 feet. Sool 3. Total cable distance between rack 3 and 9 is approximately 30 feet. . 621-110 9 4, Cable is Belden 9182 rh Remote Racks Figure 2 oneywell Industrial AuCenation and Control