Metso PDP Series Instrucciones de funcionamiento

Model PDP DPU

Installation, Preparation

and Adjustment

277573 Rev. A1

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Refer to this publication for complete and accurate information that helps you better operate and service Metso

Automation MAX Controls equipment. Your comments and suggestions are welcome.

Metso Automation MAX Controls

1180 Church Road

Lansdale, PA 19446

Attention: Manager, Technical Publications

Printed in the United States of America

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Contents

PREFACE ........................................................................................................................... III

CHAPTER 1 ......................................................................................................................1-1

Introduction................................................................................................................................................................. 1-1

Distributed Processing Unit Functionality ................................................................................................................ 1-1

Distributed Processing Unit Hardware.............................................................................................................. 1-1

Distributed Processing Unit Specifications....................................................................................................... 1-2

Mounting the DPU................................................................................................................................................ 1-2

Positioning the DPU.......................................................................................................................................... 1-2

Mounting Procedures ........................................................................................................................................ 1-3

Wiring the DPU .................................................................................................................................................... 1-3

CHAPTER 2 ......................................................................................................................2-1

DPU Front Panel.........................................................................................................................................................2-1

Overview................................................................................................................................................................... 2-1

Mode Select DIP Switch Settings.......................................................................................................................... 2-1

Data Highway Area............................................................................................................................................... 2-2

Using Rotary Switches to Set Station Address.................................................................................................. 2-2

Two LED Displays............................................................................................................................................ 2-3

IOM Load.......................................................................................................................................................... 2-3

Status Section (LEDs)........................................................................................................................................... 2-4

DPU Hardware Status LEDs............................................................................................................................. 2-4

Serial I/O and DPU Status Section.................................................................................................................... 2-4

Backup Status LEDs.......................................................................................................................................... 2-5

Reset Button.......................................................................................................................................................... 2-6

Backup Link.......................................................................................................................................................... 2-6

CPU Load.............................................................................................................................................................. 2-6

Takeover Button.................................................................................................................................................... 2-6

Backup DIP Switch Settings ................................................................................................................................. 2-6

DPU Keyswitch..................................................................................................................................................... 2-7

CHAPTER 3 ......................................................................................................................3-1

Input/Output Connections..........................................................................................................................................3-1

Data Highway............................................................................................................................................................ 3-1

ACSII Ports....................................................................................................................................................... 3-1

Model PDP DPU Installation, Preparation and Adjustment

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CHAPTER 4.......................................................................................................................4-1

DPU Battery and Fuse Maintenance.........................................................................................................................4-1

Battery Types............................................................................................................................................................4-1

Replacing the NiCd Battery Pack (Battery #2)......................................................................................................4-1

Replacing the Lithium Battery (Battery #1)..........................................................................................................4-2

Replacing DPU Fuses............................................................................................................................................4-3

CHAPTER 5.......................................................................................................................5-1

Backing up the DPU....................................................................................................................................................5-1

Overview...................................................................................................................................................................5-1

Automatic Failover/Manual Takeover...............................................................................................................5-1

Automatic Failover............................................................................................................................................5-1

Manual Takeover...............................................................................................................................................5-1

Cable Disconnect...............................................................................................................................................5-2

CHAPTER 6.......................................................................................................................6-1

Starting the DPU.........................................................................................................................................................6-1

Startup States.............................................................................................................................................................6-1

Demanding a Cold Startup ....................................................................................................................................6-2

Starting a Standalone DPU....................................................................................................................................6-2

Starting a Backup Pair of DPUs............................................................................................................................6-3

Replacing a DPU in a Backup Pair........................................................................................................................6-5

CHAPTER 7......................................................................................................................7-1

Using Interaction Pages.............................................................................................................................................7-1

Accessing Displays....................................................................................................................................................7-1

Using Interaction Page 9 Display with a Workstation...........................................................................................7-1

Startup...............................................................................................................................................................7-1

Backup Option...................................................................................................................................................7-1

Digital Input Filter Time Field ..........................................................................................................................7-2

Serial Ports Field...............................................................................................................................................7-2

Lockout and Log Options Field.........................................................................................................................7-2

Using Interaction Page 9 Display with an Operator Station..................................................................................7-2

Startup...............................................................................................................................................................7-4

Backup Option Field .........................................................................................................................................7-4

Stat Page Field...................................................................................................................................................7-4

DIO Inventory Field..........................................................................................................................................7-4

Digital Input Filter Time Field ..........................................................................................................................7-5

Analog Input Inventory Field ............................................................................................................................7-5

Redundant I/O Address Ranges Field................................................................................................................7-5

Lockout and Log Options Field.........................................................................................................................7-5

Serial Ports Field...............................................................................................................................................7-5

Interaction Page 10................................................................................................................................................7-6

Event Queue Pointer Information......................................................................................................................7-7

Interaction Page 11................................................................................................................................................7-8

Interaction Page 12................................................................................................................................................7-9

Interaction Page 13..............................................................................................................................................7-10

Contents

CHAPTER 8 .....................................................................................................................8-1

Alarms and Diagnostics..............................................................................................................................................8-1

Annunciation of Alarms............................................................................................................................................ 8-1

Front Panel Numeric LEDs............................................................................................................................... 8-1

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Preface

The Distributed Processing Unit described in this publication consists of two

models, the Model PDP001 Series and the Model PDP100 Series. From a

hardware perspective, the two models are virtually identical. At the software

level, however, the two models contain different firmware. The Version 7.1

Firmware makes the Model PDP100 Series compatible with the IEC 1131-3

toolset. The Model PDP001 Series supports Metso Automation MAX

Controls EXtended Control Engineering Language (ExCEL), a Metso

Automation MAX Controls programming language, and ladder logic.

In addition to DPU front panel controls, to a limited extent you may control

a DPU from the maxSTATION running maxVUE Runtime software.

maxVUE Runtime also lets you monitor DPU status, DPU-related alarms,

and access DPU Interaction Pages, containing data and system statistics

stored in the DPU. Interaction Pages are described in Chapter 3. For

maxVUE Runtime information, refer to Publication 277557, MaxSTATION

Operator' s Guide. You may reload a DPU's configuration from the

maxSTATION running maxTOOLS software. Refer to the maxTOOLS

online help supplied with the package for configuration installation

instructions.

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Chapter 1

Introduction

Distributed Processing Unit Functionality

The Model PDP Distributed Processing Unit (DPU) performs primary data

acquisition, control, and data processing functions for the maxDNA

Distributed Control System. The DPU is a self-contained microprocessor-

based, rack-mounted unit, which occupies a single slot in a Remote

Processing Unit cabinet. It is designed to operate with user-defined

combinations of maxDNA Model IOP Input/Output Modules, and to

communicate with other devices, such as Programmable Logic Controllers

and Remote Terminal Units.

As a station on the DPU Bus, the DPU scans and processes information for

use by other devices in the maxDNA system. Each DPU performs:

•Comprehensive alarming and calculations.

•Logging of Sequence of Events (SOE) data.

•Acquisition of trend information.

•Continuous scanning of Model IOP I/O modules.

•Execution of predefined Control and Data Blocks for process control and

data acquisition.

•Execution of user written programs using IEC1131-3 Toolset or Metso

Automation MAX Controls EXtended Control Engineering Language

(ExCEL).

•Ladder logic processing.

•Assurance of secure link-level data highway communications.

Distributed Processing Unit Hardware

A DPU consists of three circuit cards installed in a rack-mounted chassis.

The right front chassis panel contains two clockwise and counter-clockwise

connectors, two serial ports, 10 terminal blocks, and the DPU keylock.

Model PDP DPU Installation, Preparation and Adjustment

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1-2

The processor cards mounted behind the gray and white front panel consist

of the motherboard, Data Highway Card, and the Control Processor Card.

The Data Highway Card and Control Processor Card are mounted as

daughter cards on the motherboard.

Except for the Control Processor Card, the front edge of each processor card

features switches, indicator lamps, and rotary dials that are visible and

accessible from the DPU front panel.

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, 1.2 amps

Mounting the DPU The Model PDP Distributed Processing Unit (DPU) is mounted on the

Input/Output (I/O) backplane with Model IOP Input/Output modules.

Positioning the DPU

The DPU must be mounted in the right most position of the Model IOP rack

since the DPU is wider than the I/O cards and requires good air flow. In a

six-wide I/O rack, the mounting bracket to the left of the DPU must be

removed since the DPU requires an I/O panel.

When using a second DPU for backup, it must be mounted vertically

adjacent to the primary DPU.

When the DPU is installed in the right most slot, the DPU cover extends

over the J3 and J4 connectors on the back panel. The standard daisy-chain

cable (064353) is low profile, however, and will not cause any interference.

Any cables higher than 1 inch above the surface of the backplane, and any

terminators, will interfere with the cover. Some older cables, in particular,

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 MAX

Controls 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. It is a male-female adapter so that the original cable or

Introduction

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terminator can be plugged directly into the adapter out of the way of

interference with the DPU.

The DPU is designed to allow installation and removal with the +24 V dc

power supply turned on.

Mounting Procedures

Before mounting any hardware, refer to the cabling and field wiring sections

of Publication 277563, Model IOP Input/Output System Installation and Pre-

paration, for information also pertinent to mounting.

To install the DPU in the rack, refer to Chapter 6.

Wiring the DPU With the exception of the 10 point terminal block on the front panel of the

DPU chassis, no hard wiring is required. All connections between the DPU

module and the DPU chassis are made upon installation into the I/O rack.

Use maxTOOLS to create input designations for each DPU during

configuration.

Ten terminal board connectors, with #6 screws, are positioned at the lower

left side of the DPU chassis. Pin-outs are as follows:

Table 1-1. Ten Point Terminal Block

PIN No. Pur

ose

1-6 Reserved

7 Open

8, 9 DPU offline contact (photovoltaic relay, opens when the DPU is

offline)

Peak operating voltage = ±300V

Maximum load = 60 mA

On resistance = 30 Ohms

Off resistance = 1 mOhms (Contact is closed if DPU is online)

10 Circuit Groun

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Mode Select

CCW

Off

Data Highway Off

Status Jabber

IOM

Load

Stn No.

G Active

R Offline

Y Inactive State

Battery

Power

G- Tx

R- Rx

Serial Ports

G- Active

R- Error

Per IO

Prog IO

Backup

Reset

CPU Load

Backup

Link

Takeover

Pri

PIO

SIO1

SIO2 Sep

Com

Sec

DistributedProcessingUnit

Chapter 2

DPU Front Panel

Overview All DPU controls, indicator lamps,

keylock, and switches are located on the

DPU front panel. Refer to Figure 2-1,

DPU Front Panel. Use this front panel to

monitor or control different aspects of

the DPU. This chapter describes and

illustrates individual sections. The

various front panel features are generally

positioned in two vertical panel areas

corresponding to supporting processor

card positions mounted behind the front

panel.

Mode Select DIP Switch Settings

The mode switches, located at the top of

the front panel, are used during DPU

manufacturing and testing. For normal

DPU operation, all four switches should

be set to the left. Setting the B (Blank

database) SW8, 2, 1 to the left, and SW4

to the right during power on or reset

causes the DPU to erase its database and

come up cold. Once the DPU is

operational (DPU on DPU Bus), be sure

to set the mode switches back to the left.

Figure 2-1. DPU

Front Panel

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