Model PDP Series 200 maxDPU4E Hardware Guide 278590 Rev.
Refer to this publication for complete and accurate information that helps you better operate and service Metso Automation equipment. Your comments and suggestions are welcome. Metso Automation 1180 Church Road Lansdale, PA 19446 Attention: Manager, Technical Publications Copyright © 2004 by Metso Automation MAX Controls, Inc.
Contents CHAPTER 1 ...................................................................................................................... 1-1 Introduction .................................................................................................................................................................1-1 Distributed Processing Unit Functionality.................................................................................................................
Model PDP Series 200 maxDPU4E Hardware Guide Backup Link ......................................................................................................................................................... 2-2 CHAPTER 3 ...................................................................................................................... 3-1 DPU Switch Settings and Button Controls ...............................................................................................................
Contents CHAPTER 8 ...................................................................................................................... 8-1 DPU Battery and Fuse Maintenance .........................................................................................................................8-1 Battery and Fuse Types .............................................................................................................................................8-1 Replacing the NiCd Battery Pack ............
Chapter 1 Introduction Distributed Processing Unit Functionality The Model PDP Distributed Processing Unit (maxDPU4E), which runs under the Windows CE real-time multitasking operating system, is the hardware processing engine of the maxDNA distributed control system. The maxDPU4E performs primary data acquisition, control, and data processing functions.
Model PDP Series 200 maxDPU4E Hardware Guide Control Processor The DPU itself consists of a main board and a Control Processor daughter card known as the Intel Embedded Pentium Processor Module. The Control Processor interfaces with 64MByte DRAM, a PCI Bus, and 8MByte of Flash memory. Performance A multispeed processing system is built into the maxDPU4E, which allows objects to be executed in four different time classes from as fast as 20msec to 1 second.
Introduction • • • • • • Battery test DRAM parity errors Watch dog tests Memory integrity tests Power supplies level checks Active Pulse frequency check IOM Diagnostics During Startup the IOM performs the following tests: • Flash checksum test • FPGA configuration test • DPRAM integrity test • FPGA RAM integrity test • IO Bus integrity test During normal operation the IOM performs the following tests: • Flash checksum test • IO Bus diagnostics on inactive DPU • Watch dog tests Fully Self Describing Objec
Model PDP Series 200 maxDPU4E Hardware Guide second and state changes are time stamped with 1 ms resolution and stored in the DPU's 10,000-event buffer. Each input has a separately configurable digital filter for contact debounce. Distributed Processing Unit Specifications Operating temperature range 0 to 60 degrees C Storage temperature range (-)25 to 70 degrees C Relative humidity range 5 to 90% noncondensing Power requirements 24 VDC ±4 VDC Current: 1.
Introduction will interfere with the DPU cover. It may be possible to move the terminator to the other end of the daisy chain or to rearrange the order of the daisy-chain cables to eliminate the interference. If this is not possible, a cable adapter is available (Metso Automation Part Number 081580). This adapter has a metal bracket which mounts to the power strut and a 12-inch connecting cable plugs into J3 or J4 on the back panel.
Model PDP Series 200 maxDPU4E Hardware Guide Serial port 1 is a nine pin RS-232C port that is used to update the DPU BIOS and firmware, if necessary. Serial port 2 is a twenty-five-pin serial port that supports multiple interface standards. This port will be used by the DPU to interface with external PLC type equipment. maxNET Interface Ports Dual Ethernet 10Base-T ports are provided to interface with the maxNET communication network. These ports run at 10Mbps, full-duplex.
Introduction DPU Front Panel The DPU Front Panel, which attaches to the DPU chassis, contains 13 LEDs and pushbuttons for Reset and Takeover. The meaning of the LEDs can change depending upon the operational mode of the DPU. The list below represents their function during normal operation. Network Status LEDs These LEDs report the status of maxNET Network A and B links, and the DPU backup link. Serial Port LEDs These LEDs report the status of the two serial ports.
Model PDP Series 200 maxDPU4E Hardware Guide Pressing the Takeover button can force a previously inactive DPU to go active. This should not be done casually as a manually forced takeover occurs regardless of the inactive DPU’s ability to control. This can have severe consequences to your process. Refer to Chapter 3 for more detailed information on the use of this button. 1-8 Metso Automation MAX Controls Inc.
Chapter 2 DPU Chassis Input/Output Connections Overview All input/output connections are contained on the front DPU chassis panel. The chassis contains: • • • Two serial ports Two 10Base-T Ethernet ports One backup link port This chapter describes each link in some detail. Ethernet Network Connections The DPU chassis contains two 10Base-T Ethernet ports using RJ-45 connectors to interface with the maxNET communication network. Network A and Network B operate at 10Mbps as independent networks.
Model PDP Series 200 maxDPU4E Hardware Guide Serial Ports The DPU front chassis panel contains two serial ports, a female 9-pin D style RS232C connector and a female 25-pin D-type connector. The 9-pin RS232C connector is used to flash the DPU firmware with updates. The 25-pin D-type connector may be configured, by software, to support several different interface standards. Table 2-1 provides the pin-outs for the 9-pin port. The pinouts of the 25-pin port depends upon its usage. Table 2-1.
Chapter 3 DPU Switch Settings and Button Controls Overview The DPU chassis contains four hexadecimal rotary switches (labeled S1-S4) and a key lock switch, while the DPU front panel contains pushbuttons for Reset and Takeover. The three Network rotary address switches (S1, S2 and S3) are used to establish part of the DPU’s IP address, while the mode switch (S4) is used to determine the operational mode of the DPU during startup.
Model PDP Series 200 maxDPU4E Hardware Guide Hexadecimal 0 1 2 3 4 5 6 7 8 9 A B C D E F Decimal 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 To convert a two-digit hexadecimal number to decimal, multiply the first digit by 16 and add the decimal value of the second digit.
DPU Switch Settings and Button Controls F X new CE code image and store it into flash memory. See Chapter 5, "Installing CP Firmware Flash Via Network Download." Normal operating mode. Will use the database stored in flash if available. DPU Key Switch Use the DPU key switch, located at the bottom part of the DPU chassis, to select one of four operating modes. The DPU can operate with the key in place or removed; you can remove the key from the switch regardless of key position.
Model PDP Series 200 maxDPU4E Hardware Guide Using the Takeover Button Pressing the Takeover button can force a previously inactive DPU to go active. This should not be done casually as a manually forced takeover occurs regardless of the inactive DPU’s ability to control. This can have severe consequences to your process. If the Takeover button is pressed on an inactive standalone DPU (i.e., backup is not enabled), the inactive DPU will go active regardless of its health, database, or key switch position.
Chapter 4 Interpreting Status LEDs Overview Refer to this chapter when you need to interpret the meanings of the 13 status LEDs on the DPU front panel. At various times the LEDs flash green, yellow, red or display no color to indicate the associated hardware’s functional status. Discussions in the following sections explain what the color changes may indicate under different DPU states.
Model PDP Series 200 maxDPU4E Hardware Guide • • • Database save and recovery During installation of new software image in flash memory When an error condition is detected The following two tables list LED colors states during a DPU boot and during normal operation, respectively.
Interpreting Status LEDs Interpreting LED Status during Normal DPU Operation LED Network A Network B Network Backup Serial Port 1 Serial Port 2 DI queue* Green Network A Operational Network B Operational Backup Network Operational Yellow Some Network A Failures Some Network B Failures Some Backup Network Failures Database Reloaded from Flash After Reset Database Reloaded from Flash After Reset All configured DI cards are working correctly IP Mismatch Caused Clearing of Flash Database N/A Red Network
Model PDP Series 200 maxDPU4E Hardware Guide Interpreting I/O LED Status during Normal DPU Operation The four I/O LEDs display the status of each of the four I/O queues. In general, the I/O cards of a given type are assigned to the labeled LEDs; however, due to I/O bus transaction processing requirements, some of the I/O modules of different types or different applications are assigned to different queues. The following table shows the queue assignments for each type or application of an I/O module.
Interpreting Status LEDs Examples of how to read the LED codes are shown below. Your LEDs may be labeled differently but the LSB will still at the top and the MSB at the bottom. The causes of the errors indicated by these codes are not user repairable. If these LEDs flash any error code, return the DPU to the factory for repair. DI (1) DI (1) DI (1) AO/DO (2) AO/DO (2) AO/DO (2) AI (4) AI (4) AI (4) (8) Example 1 (8) Example 2 (8) Example 3 Example 1 – All LEDs are off.
Model PDP Series 200 maxDPU4E Hardware Guide IOM LED Error Codes 4-6 Flashing LED Color All Off Binary Number in LEDs (DI is LSB) 0 not used Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Interrupt Interrupt Interrupt Interrupt Interrupt not used Interrupt Interrupt Interrupt not used not used not used not used not used not used Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yel
Interpreting Status LEDs DPU LED States when Starting as Standalone or Backup DPU While the DPU is being restarted, the State Led moves through various color cycles as it goes to a Standalone state or Redundant Configuration state with or without a working backup DPU. Use the following table for an understanding of the state transitions.
Model PDP Series 200 maxDPU4E Hardware Guide During the restart, the serial port LEDs provide an indication of the health of the database image. If both LEDs are green, the database is good. The DPU will not load a database that it determines to be bad. Besides a bad database, there is one other condition that will prevent a saved database from being reloaded.
Chapter 5 Installing Windows CE and maxDNA Software into DPU Flash Memory Overview The DPU contains more than 8 megabytes of flash memory for non-volatile storage of configuration data and associated firmware.
Model PDP Series 200 maxDPU4E Hardware Guide Flashing CP & IOM Firmware via Network Download To perform a flash upgrade over the network, use the maxDPU4E flash program at a maxSTATION. Should you experience continuous problems with a network upgrade then, as a backup, you may perform the upgrade using the 9-pin serial port located on the DPU chassis. This chapter explains how to install firmware using either approach. To download firmware over the maxNET network: 1.
Installing Windows CE and maxDNA Software into DPU Flash Memory Note: Under special circumstances the check box, labeled No IOM Download, can be checked to skip the download of the IOM. Note: the software will always download from the c:\mcs\setup folder, so if an alternate file is to be downloaded, the file must be located in c:\mcs\setup. WARNING - New DPUs are normally shipped with the latest production versions of firmware. However, you may be running an older version at your plant.
Model PDP Series 200 maxDPU4E Hardware Guide 2. Place the DPU4E mode switch in the “C” position. 3. Press the reset button on the DPU to be serial downloaded. Make sure that the key switch is halfway between valid positions to allow a hard reset to take place. 4. Wait for the Serial 1 LED to light on the DPU to signify that it is ready for download. 5. Boot the PC to DOS. Do not open a DOS window from within MS Windows. 6. Move the nk.bin and serflsh.
Chapter 6 Redundant DPU Operation Overview In a redundant configuration, two DPUs are connected to form a backup pair. One DPU is designated as the primary unit and the other DPU the secondary unit. The IP address of the secondary DPU is always one number greater than the address of the primary DPU. The Primary is always the even address while the Secondary is the odd address.
Model PDP Series 200 maxDPU4E Hardware Guide database). If a severe diagnostic alarm or a fatal alarm condition exists in the inactive DPU then the Takeover button will be ignored. For a more complete discussion of manual takeover, see Chapter 3, “Using the Manual Takeover Button.” 6-2 Metso Automation MAX Controls Inc.
Chapter 7 Starting the DPU Startup States Refer to this chapter to learn how to: • • • Start a standalone DPU Start DPUs in a backup pair Replace a DPU in a backup pair When a DPU boots, it checks for a valid configuration and database existing in its flash memory and proceeds to load it if one is found. The DPU then listens over the backup link to see if another DPU is active and in control before it operates on the loaded configuration.
Model PDP Series 200 maxDPU4E Hardware Guide It is also possible for the DPU to automatically clear its database. When the DPU starts up, it reads its IP address from the switches on the chassis panel. If the DPU has a database, it compares the switch address with the address in its database. If they are different, the DPU will clear its database. This is a safety measure that is intended to prevent incorrect control operation that might otherwise be caused by installing a loaded DPU in the wrong chassis.
Starting the DPU 12. Verify that the Net A and Net B LEDs are green. 13. Verify that the Backup LED is off. 14. Verify that the CP LED is blinking green/yellow. 15. Verify that the IOM LED is green. 16. Verify that the State LED is green. 17. Verify that four I/O LEDs are off (there is no database in the DPU). 18. Verify the DPU shows up as healthy in the HealthLog list and that it is communicating on the network. 19.
Model PDP Series 200 maxDPU4E Hardware Guide 3. Verify that the NiCd battery pack is plugged in to connector J13 on each DPU (refer to the chapter on battery and fuse maintenance). 4. Verify that the Backup cable is connected to both the primary and secondary DPU. 5. Verify the proper IP Address is set in the Network Address switches. 6. Position each DPU into the top and bottom card guides of the chassis but do not push them in all of the way. 7.
Starting the DPU 22. It will take up to about a minute for a blank DPU to boot (if a DPU has a large database, the boot time can be up to about 2 minutes). 23. Return the Mode switch to “F.” 24. Verify that the battery test passes (Battery LED is green.). This can take up to about another minute. 25. Verify that the Net A and Net B LEDs are green. 26. Verify that the CP LED is blinking green/yellow. 27. Verify that the IOM LED is green. 28.
Model PDP Series 200 maxDPU4E Hardware Guide 40. Acknowledge all alarms from the DPU pair and make sure that alarms are all clear. 41. Place the key switch of the secondary DPU in the Run or Locked mode. Replacing a DPU in a Backup Pair When replacing a DPU in a backup pair, it is necessary to prevent the new unit from gaining control until it is properly configured and up to date. Perform the following steps to ensure that an unexpected failover does not occur during the replacement process.
Starting the DPU 11. Verify DPU progresses from blank state to warming to hot standby via the LEDs and via the Backup Atom attributes as viewed from the Point Browser at the maxSTATION. 12. Acknowledge all alarms from the new DPU. 13. Place the key switch of the new DPU in the Run or Locked mode. 14. If the new DPU is the primary of the pair, wait at least 30 seconds to allow its configuration and database to be updated, then press its Takeover button to give it control. 15.
Chapter 8 DPU Battery and Fuse Maintenance Battery and Fuse Types The maxDPU4E comes with a single battery and two fuses that may need attention. The Model PDP DPU uses a Nickel Cadmium (NiCd) rechargeable battery pack that must be replaced periodically. The NiCd battery pack, mounted on the DPU cover, allows the DPU to sustain operation for several seconds after 24V power loss while the current configuration is stored in flash memory.
Model PDP Series 200 maxDPU4E Hardware Guide The DPU NiCd battery pack (Part number 081537) should be replaced at least every three years. Spare NiCd battery packs have a shelf life of 5 to 7 years. The battery is located in an accessible compartment attached to the DPU cover on the upper right side of the DPU. To access the battery, you must remove the DPU from the rack as described in the following procedure: To replace the battery: 1.
DPU Battery and Fuse Maintenance 2. Gently slide the DPU module out of the cabinet rack and set the unit down on an appropriate work surface, component side up. 3. Locate the battery compartment on the upper right side and remove the battery plug from the J13 connector. 4. Remove the top metal cover. 5. Locate the fuse to be replaced. Both fuses are located on the upper right side of the motherboard. 6. Carefully remove the fuse by pulling it straight up.
Appendix A DPU4E Maintenance Utilities Overview This section contains information regarding programming the following parts on the DPU4E: • CPLD – Complex Programmable Logic Device • BIOS – Embedded BIOS + ROM Extension • IOM – Input Output Module Flash Firmware These procedures require special equipment and training. They are intended for use by Metso Automation personnel.
Model PDP Series 200 maxDPU4E Hardware Guide • 9 pin Male to Male Gender Changer, Metso Automation part #050100 • IOM Reset Cable (10-pin ribbon cable connector with pins 5 and 7 connected together), Metso Automation part #050101 • PC104 to ISA-bus adapter (*) with the following ISA cards: • VGA video card (*) and a VGA monitor(*) • Disk-On-Chip card with MS-DOS 6.x or later (*) • Or, a SCSI HD/floppy controller (*) (Adaptec AHA1542B or equivalent) and a small SCSI hard disk loaded with MS-DOS 6.
DPU4E Maintenance Utilities On the PC, press “Start”, “PROGRAMS”, and select the Altera MAX+plus II application. The opening screen is shown below. If MAX+plus II is not already installed on your PC, follow the installation instructions later in this chapter. Figure 1 Select “Programmer” from the MAX+plus II pull down menu. The Programmer window will appear as shown in Figure 2.
Model PDP Series 200 maxDPU4E Hardware Guide Figure 2 Make sure the ByteBlaster cable is connected to the PC and DPU or else the setup will be different. Click on the “JTAG” pull down menu heading (top line of the MAX+plus II window) if this is the first time that a DPU4E is being programmed from this PC. Select “Multi-Device JTAG Chain Setup” (See Figure 3). Set the Device Name to “EPM7192S”. Select “ADD”. Select “Device 1” to highlight it. Click the button labeled “Select Programming File…”.
DPU4E Maintenance Utilities If prompted to setup the programming hardware then choose ByteBlaster as the type and LPT1 as the port. If prompted, click the “Detect JTAG Chain Info” button to verify that the DPU and PC are properly connected. As the programming and verification steps occur, their progress will be shown in bar chart form near the top of the programming window.
Model PDP Series 200 maxDPU4E Hardware Guide Figure 3 A-6 Metso Automation MAX Controls Inc.
DPU4E Maintenance Utilities Installation of the Altera MAX+Plus II Programming Utility These instructions apply for Microsoft Windows 95 and Windows NT Copy ASAP2.EXE into “\dpu4e\altera” directory. The file may be found on the maxDNA installation CD in the Utilities\DPU4E_CPLD folder. Run “ASAP2.exe”. That will create “files.exe”. Run “files.exe –d” from a command prompt (The “-d” suffix creates the desired directory structure).
Model PDP Series 200 maxDPU4E Hardware Guide Attach the Null Modem serial port cable (Laplink Metso #046853) between the PC and the DPU Chassis’s 9-pin connector. Use the 9-pin Male-to-Male Gender Changer (Metso Automation #050100) if necessary. Make note of which PC comm port (e.g., 1 or 2) being used. Set the DPU Mode Switch on to “4”. Power up the DPU. Change the directory to \DPU4E\BIOS. Make sure latest BIOS.ROM, embflash.exe, client.bin and platform.* files exist in the working directory, \DPU4E\BIOS.
DPU4E Maintenance Utilities CP Initial Flash Programming Utility Set the DPU Mode Switch to “0”. Connect the PC104 cables between the ISA-bus Adapter and the DPU’s PC104 Connector (Make sure pin 1 of both cables are closest to the center of the board. Plug the video card and Disk-On-Chip card (or SCSI controller) into the ISA bus connectors. Connect the VGA monitor to the video card. Connect the hard disk to the SCSI controller if you are using one. Connect the ISA-bus power supply to the ISA adapter.
Model PDP Series 200 maxDPU4E Hardware Guide NOTES: 1. If the DPU is part of a backup pair, both DPUs must be updated. However, the inactive/off-line DPU can be flashed while the other DPU is in control. Then follow the procedures for bringing up a backup DPU and transferring control so that the other DPU can be flashed. 2. This procedure must be run from DOS (not from a DOS window). 3.
DPU4E Maintenance Utilities located toward the middle of the board when the board is stood up as if inserted in a rack. Insert the DPU into the chassis. At the PC’s DOS prompt (C:\) type: CD PEBDM . At the PC’s DOS prompt (C:\PEBDM\) type: PROG32. The program will display a menu and status screen. Press . On the displayed menu screen cursor to the selection: RE Reset . Cursor to CM Choose Algorithm Module .
Model PDP Series 200 maxDPU4E Hardware Guide On the displayed menu screen cursor down to the selection: PM Program Module . The bottom of the display should show the program status: Programming. Programmed. On the displayed menu screen cursor down to the selection: VM Verify Module. . The bottom of the display should show the program status: Verifying. Verified. If an error in the programming or verification is reported, then start over.
