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6 Removal and Replacement

6.7 HPMM or IOP Card Case Replacement

420 HPM High-Performance Process Manager Service R688

Honeywell December 2020

Card case illustration

Figure 206 Replacing HPMM or IOP Card Case

Main Page

Table of Contents9
Introduction29
Overview29
Purpose of this Manual29
Service Philosophy29
Equipment Description31
Overview31
Introduction31
Component Part Numbers31
Power System Controls31
Power Supply Module Control31
HPMM/IOP Card Power Interrupt Switches31
HPM Subsystem Overview32
Major Assemblies32
Card File Types32
Card File Designations33
Nonredundant 15-Slot HPMM Card File33
Redundant 15-Slot HPMM Card Files33
Nonredundant 7-Slot HPMM Card File33
Redundant 7-Slot HPMM Card Files33
Nonredundant HPMM Cabinet Layout34
Figure 1 Cabinet Layout - HPM with Nonredundant HPMM34
HPMM and IOP Card Files35
Introduction35
HPMM and IOP Card File Differences35
Non-CE Compliant Card File Models35
CE Compliant Card File Models35
Conversion Kit35
HPMM Card Files35
Table 1 Card File Models35
HPMM Card File Configurations36
15-Slot HPMM Card File37
Figure 2 15-Slot HPMM Card File37
HPMM Functionality38
HPMM Card/Module Types38
Card/Module Illustrations38
Table 2 HPMM Card/Module Types38
Power Indicators39
Status Indicators39
Diagnostic Display39
Diagnostic Display Analysis Example40
Detailed Diagnostic Display Switch40
Debug Connector40
HPMM +5 Volt Power Margins41
HPM UCN Interface Module Illustration41
Figure 3 HPM UCN Interface Module (Front Panel)41
High-Performance Comm/Control Card42
Figure 4 High-Performance Comm/Control Card (Front Panel)42
High-Performance I/O Link Card43
Figure 5 High-Performance I/O Link Card (Front Panel)43
EHPM Card Files44
Introduction44
EHPM Card File Configurations44
15-Slot EHPM Card File45
EHPM Functionality46
EHPM Card/Module Types46
Card/Module Illustrations47
Power Indicators47
Status Indicators47
Diagnostic Display47
Diagnostic Display Analysis Example48
Detailed Diagnostic Display Switch48
Debug Connector48
EHPM +5 Volt Power Margins49
EHPM FTE Interface Module49
CF9 Ethernet Switch50
Enhanced High-Performance Comm/Control Card50
EHPM Front Panel LED Display Information51
Service Failed EHPM Cards Flashed with Experion-Integrated Firmware52
Overview52
EHPM Comm/Ctrl Card Replacement Procedure52
IOP Card Files55
Introduction55
Total Number of Card Files55
Remote Card File Installation55
Total Number of Iops55
15-Slot IOP Card File56
Figure 6 15-Slot IOP Card File56
Types of Input/Output Processors (Iops)57
AO and DO Iops57
Redundant Iops57
Redundant HLAI Iops58
Figure 7HLAI FTA with Redundant HLAI Iops58
Redundant AO Iops59
Figure 8 Analog Output FTA with Redundant Analog Output Iops59
Low Level Multiplexer IOP (Llmux)60
Figure 9 Low Level Multiplexer Interconnections60
Field Termination Assemblies for IOP61
Two Types of Ftas61
Power Adapter61
Remote Hardened Low Level Multiplexer IOP (RHMUX)61
RHMUX Thermocouple FTA62
FTA and Power Adapter Installation62
Figure 10 Remote Hardened Low Level Multiplexer Interconnections62
IOP to Power Adapter Connection63
Power Adapter to FTA Connection63
Power Adapter Indicators63
Serial Device Interface IOP (SDI)63
Introduction63
SDI Interface Configuration64
Figure 11 Serial Device Interface Interconnections64
EIA-232 and EIA--422/485 Interfaces65
EIA-232 Interface Cable Length65
EIA-422/485 Cable Length Limitation65
Power Adapter Installation65
SDI FTA Installation65
FTA to Power Adapter Interface65
Model MU-TSDT02 FTA65
Model MU-TSDM02 FTA65
Model MU-TSDU02 FTA65
Cabling Information65
Serial Interface IOP (SI)66
Introduction66
EIA-232 and EIA-422/485 Interfaces66
Point-To-Point or Multidrop Interfaces66
EIA Interface Limitations66
Power Adapter Installation66
Power Adapter Size66
New si IOP Slot Summary Display to View Array Points Built on the si FTA66
Model MU-TSIM12 Interconnections67
Figure 12 Model MU-TSIM12 Serial Interface FTA Interconnections67
SI FTA Installation68
FTA to Power Adapter Interface68
Cabling Information68
Model MU-TSIA12 EIA-232 Interface68
Model MU-TSIM12 EIA-232 Interface68
Model MU-TSIM22 EIA-422/485 Interface68
I/O Link Extender (Fiber Optic Link)69
Introduction69
See the Following Figures69
Features and Guidelines70
Front Panel Indicators70
Status Indicator Operation70
Standard I/O Link Extender Connections Nonredundant HPMM71
Figure 13 Standard I/O Link Extender Interconnections with Nonredundant HPMM71
Standard I/O Link Extender Connections Redundant Hpmms72
Figure 14 Standard I/O Link Extender Interconnections with Redundant Hpmms72
Long Distance I/O Link Extender Connections Nonredundant HPMM73
Figure 15 Long Distance I/O Link Extender Interconnections with Nonredundant HPMM73
Long Distance I/O Link Extender Connections Redundant Hpmms74
Figure 16 Long Distance I/O Link Extender Interconnections with Redundant Hpmms74
2.13 Field Termination Assembly75
Terminal Connectors75
Ftas Types75
Model and Part Numbers75
Detailed Descriptions75
Standard Ftas75
Table 3 Standard Field Termination Assembly Types75
Galvanically Isolated Ftas77
Three Physical Sizes77
Table 4 Galvanically Isolated Field Termination Assembly Types77
FTA Mounting Channels78
Figure 17 Field Termination Assembly (FTA) Sizes78
Vertical Orientation79
Horizontal Orientation79
Typical Cabinet Layout80
Figure 18 Typical Vertical FTA Mounting Channel Layout80
Compression or Screw Terminals Available81
FTA Compression-Type Terminal Connector81
Figure 19 Typical FTA Compression Terminal Connector81
FTA Fixed Screw Terminal Connector82
FTA Removable Screw-Type Connector82
Figure 20 Typical FTA Fixed Screw Terminal Connector82
Figure 21 Typical FTA Removable Screw Terminal Connector82
Galvanic Isolation Module Connectors83
Crimp Pin-Type Terminal Connector83
Figure 22 Crimp-Type Galvanic Isolation Module Terminal Connector83
Compression-Type Terminal Connector84
Figure 23 Compression-Type Galvanic Isolation Module Terminal Connector84
2.14 FTA Mounting Channels85
Introduction85
Location85
Number of FTA Mounting Channels85
Vertical FTA Mounting Channels85
Horizontal FTA Mounting Channels85
Dual Access Cabinet Installation86
Figure 24 Vertical FTA Mounting Channel Installation - Dual Access Cabinet86
Figure 25 Vertical FTA Mounting Channel Installation - CF9 Mounting87
Single Access Cabinet Installation88
Figure 26 Vertical FTA Mounting Channel Installation - Single Access Cabinet88
2.15 Power Systems89
Power System Features89
Standard Power System89
48 Volt Battery Backup Time Duration89
CMOS Backup Time Duration90
PSM Redundancy Requirements90
Early Production Standard Power System91
Figure 27 Standard Power System91
HPM Standard Power System92
Figure 28 HPM Standard Power System92
AC Only Power System93
Figure 29 AC Only Power System93
2.16 Power Distribution94
Overview94
AC Only Power System Ac Power94
Battery Backup Module94
Figure 30 Power Distribution94
48 Volt Battery Switch95
No Battery Backup (Early Production Standard Power System)95
Figure 31 Standard Power System Backpanel (Early Production)95
No Battery Backup (HPM Standard Power System)96
CMOS Battery Backup96
Figure 32 HPM Standard Power System Backpanel96
Standard Power System (Early Production)97
Figure 33 CMOS Battery Backup Assembly (Early Production)97
HPM Standard Power System98
AC Only Power System98
Figure 34 CMOS Battery Backup Assembly (HPM Standard Power System)98
2.17 24 VDC Power Distribution99
Dual Power Distribution Cables99
Standard Power System99
AC Only Power System99
Typical Cabinet Power Distribution99
Figure 35 Typical Cabinet 24 VDC Power Distribution99
2.18 Cabinet Fan Assembly100
Introduction100
Up to Four Cabinet Fan Assemblies100
Optional Cabinet Fan Assembly100
2.19 LLAI Line Frequency Clock Voltage100
Standard Power System100
AC Only Power System100
2.20 24 VDC Fuse Protection101
Card File Fusing101
Fuse Removal101
Fuse Extraction101
Fuse Insertion102
Left 7-Slot Card File102
Left 7-Slot Card File Fuse Protection102
Table 5 Left 7-Slot Card File Fuse Protection102
Left 7-Slot HPMM Card File 24 VDC Distribution103
Figure 36 Left 7-Slot HPMM Card File Backpanel 24 VDC Distribution103
Left 7-Slot IOP Card File 24 VDC Distribution104
Figure 37 Left 7-Slot IOP Card File Backpanel 24 VDC Distribution104
Left 7-Slot Card File Backpanel Fuse Locations105
Figure 38 Left 7-Slot Card File Backpanel Fuse Locations105
Figure 39 Left 7-Slot Card File Backpanel Fuse Locations for EHPM105
Right 7-Slot Card File106
Right 7-Slot Card File Backpanel Fuse Protection106
Table 6 Right 7-Slot Card File Backpanel Fuse Protection106
Right 7-Slot HPMM Card File 24 VDC Distribution107
Figure 40 Right 7-Slot HPMM Card File Backpanel 24 VDC Distribution107
Right 7-Slot IOP Card File 24 VDC Distribution108
Figure 41 Right 7-Slot IOP Card File Backpanel 24 VDC Distribution108
Right 7-Slot Card File Backpanel Fuse Locations109
Figure 42 Right 7-Slot Card File Backpanel Fuse Locations109
Figure 43 Right 7-Slot Card File Backpanel Fuse Locations for EHPM109
15-Slot Card File110
15-Slot Card File Backpanel Fuse Protection110
Table 7 15-Slot Card File Backpanel Fuse Protection110
15-Slot HPMM Card File 24 VDC Distribution111
Figure 44 15-Slot HPMM Card File Backpanel 24 VDC Distribution111
15-Slot IOP Card File 24 VDC Distribution112
Figure 45 15-Slot IOP Card File Backpanel 24 VDC Distribution112
15-Slot Card File Backpanel Fuse Locations113
Figure 46 15-Slot Card File Backpanel Fuse Locations113
Figure 47 15-Slot Card File Backpanel Fuse Locations113
IOP Only Card File114
IOP Only Card File Assemblies114
IOP Only Card File Fuse Protection115
Table 8 IOP Only Card File Fuse Protection115
IOP Only Card File 24 VDC Power Distribution116
IOP Only Card File Backpanel Fuse Locations116
Figure 48 IOP Only Card File Backpanel 24 VDC Power Distribution116
FTA Fuse Protection117
Figure 49 IOP Only Card File Backpanel Fuse Locations117
Cabinet Fan Assembly Fuse Protection118
2.21 5 VDC Fuse Protection118
High-Performance I/O Link Card118
HPMM Power Routing and Fuses119
Figure 50 HPMM Power Routing and Fuses119
2.22 Card File Power Cabling120
Card File Power Connectors120
Power Distribution Assemblies120
Power System Power Connectors120
Power Distribution Examples120
Power Distribution Methods120
Table 9 Card File Power Cabling120
15-Slot Card File with Power Distribution Assemblies121
Figure 51 15-Slot Card File with Power Distribution Assemblies121
Two 15-Slot Card Files with Power Distribution Assemblies122
Figure 52 Two 15-Slot Card Files with Power Distribution Assemblies122
Three 15-Slot Card Files123
Figure 53 Three 15-Slot Card Files123
Three 15-Slot Card Files with Power Distribution Assemblies124
Power Distribution Assemblies for Redundant Cabling124
Figure 54 Three 15-Slot Card Files with Power Distribution Assemblies124
2.23 I/O Link Interface Cabling125
Introduction125
Table 10 I/O Link Interface Cabling Card File Connector Assignments125
Figure 55 Power Distribution Assemblies for Redundant Cabling125
Cable Length126
Redundant Cables126
No Cable Termination126
I/O Link Interface Cabling - Three Card Files127
Figure 56 Three Card Files127
I/O Link Interface - Four Card Files128
Figure 57 Four Card Files128
I/O Link Interface Cables in Adjacent Cabinets129
I/O Link Interface Cable Shield Grounding (Non-CE Compliance)129
I/O Link Interface Cable Shield Grounding (CE Compliance)129
Induced Power Surge Protection129
New and Upgraded Subsystems Only130
Surge Protection Network Power Cables131
I/O Link Cable Connection131
Figure 58 Surge Protection Network Power Cables131
Typical I/O Link and Power Cable Connection132
Figure 59 I/O Link Interface Cable Connection to Power Cable132
Figure 60 Typical Cabinet Surge Protection Network Cable Connections132
Power Cable I/O Link Protector Adapters134
Figure 61 Power Cable I/O Link Protector Adapters134
2.24 IOP to FTA Cabling135
Introduction135
Standard Ftas135
Galvanically Isolated Ftas135
External Cabinet Installation135
Typical Cable Routing136
Figure 62 IOP to FTA Cabinet Cabling136
2.25 Power Adapter Cabling137
Introduction137
Llmux Interconnections137
Figure 63 Power Adapter Interconnections - Llmux Application137
SDI Interconnections138
SI Interconnections138
Figure 64 Power Adapter Interconnections - SDI Application138
2.26 UCN Cable System139
Introduction139
Figure 65 Power Adapter Interconnections - si Application139
Figure 66 Universal Control Network (UCN) Components139
Redundant UCN Cables140
Cable Tap Types141
Cable Tap Usage141
Figure 67 UCN Taps141
Isolated Port Identification142
Card File Backpanel Connections142
2.27 EUCN Cable System142
Introduction142
Figure 68 UCN Drop Cable Connections to a 7-Slot HPMM Card File142
Figure 69 Enhanced Universal Control Network (EUCN) Components143
Redundant EUCN FTE Cables144
FTESTS Cable Error Scenarios144
Table 11 EHPM Cable Faults144
Table 12 ENIM Cable Faults144
Table 13 Crossover Cable Faults146
Table 14 EUCN Crossed Cable Faults146
Cable Troubleshooting Guidelines for EUCN147
Table 15 ENB Network Topology Terminology148
Figure 70: ENB Network Topology Example148
Table 16 ENB Cable Faults149
Table 17 EHPM Cable Faults151
Table 18 UCN Node (PM/APM/HPM) Cable Faults (Primary NIM Node Is an ENB)152
Table 19 UCN Node (PM/APM/HPM) Cable Faults (Primary NIM Node Is a NIM)153
Table 20 CF9 Switch/Uplink Port Failure154
Table 21 ES-T/ESVT FTE Cable Faults154
Diagnosing Complex EUCN FTE Network Faults155
Table 22 Crossover Cable Faults155
Figure 71 $FTESTS2 View - EST05 Has Cable a Fault156
Figure 72 FTE Status from View of EST05 - EST05 Has Cable a Fault156
Figure 73 UCN Status for L1 Switch a down and CF9 B Downlink Fault157
Figure 74 $FTESTS for L1 Switch a down and CF9 B Downlink Fault157
EUCN Switches158
Card File Backpanel Connections158
Figure 75 Control Firewall (CF9)158
Figure 76 Ethernet Switch158
Status Indicators on the FTE Switch159
Figure 77 Drop Cable Connections to a 7-Slot HPMM Card File for EHPM159
Control Firewall Status Indicators162
2.28 UCN Node Address Pinning164
Introduction164
One or Two HPMM Card Files164
Odd Address Pinning164
Secondary HPMM Determination164
Two Methods of Pinning164
7-Slot Card File Pinning165
Figure 78 Left 7-Slot Card File UCN Node Address Pinning165
15-Slot Card File Pinning166
Two Pinning Methods166
Pinning Method Differences166
Figure 79 15-Slot Card File UCN Node Address Pinning166
Odd Number of Jumpers Required167
Plug Jumper Method167
Figure 80 UCN Node Address Pinning Using Plug Jumpers167
Zero-Ohm Jumper Method168
Figure 81 UCN Node Address Pinning Using Zero-Ohm Resistors168
FTE Device Index Addressing169
Figure 82 - EHPM FTE Interface Module169
2.29 I/O Link Interface Address Pinning170
Introduction170
I/O Link Interface Configuration170
Consecutive Address Assignment170
Two Methods of Pinning170
Nonredundant HPMM Subsystem171
7-Slot Card Files171
Figure 83 Left 7-Slot Card File I/O Link Interface Address Pinning171
15-Slot Card File Redundant HPMM Subsystem172
7-Slot Card File Redundant HPM Subsystem172
Figure 84 15-Slot Card File I/O Link Interface Address Pinning172
IOP Only Card File Pinning Location173
Two Pinning Methods173
One Method Only173
Figure 85 IOP Only Card File I/O Link Interface Address Pinning173
Jumper Method Example174
Figure 86 Left 7-Slot Card File I/O Link Interface Address Pinning with Plug Jumpers174
Zero-Ohm Resistor Jumper Pinning Example175
Figure 87 Left 7-Slot Card File I/O Link Interface Address Pinning with Zero-Ohm Resistors175
2.30 Firmware/Hardware/Software Correlation176
Relationship176
Ucn Status Displays179
Overview179
Introduction179
References179
Release 600 Software Displays179
Display Definitions179
IOM Definition179
Target Selection179
NIM Detail Status Displays179
HPMM Detail Status Displays180
IOP Detail Status Displays180
Detail Status Display Selection Procedures180
Introduction180
NIM Detail Status Display Procedure180
System Status Display181
Figure 88 System Status Display181
UCN Status Display182
Figure 89 UCN Status Display182
Figure 90 UCN Status Display - EHPM/ENIM182
NIM Detail Status Display184
Figure 91 NIM Detail Status Display184
HPMM Detail Status Display Procedure185
HPM Status Display185
Figure 92 HPM Status Display185
Figure 93 HPM Status Display - EHPM186
Primary HPMM Detail Status Display187
Figure 94 Primary HPMM Detail Status Display187
Secondary HPMM Detail Status Display188
Figure 95 Secondary HPMM Detail Status Display188
IOP Detail Status Display Procedure189
IOP Detail Status Display189
Figure 96 IOP Detail Status Display189
Display Operation190
Introduction190
UCN Status Displays190
Figure 97 UCN Status Display190
Three Display Sections191
Device Status191
Table 23 UCN Status Display - UCN/NIM Status191
Auxillary Status192
Selecting the Status Box Target192
Primary HPMM Status192
Table 24 UCN Status Display - Primary HPMM Status192
Secondary HPMM Status193
Table 25 UCN Status Display - Secondary HPMM Status193
LOAD/SAVE RESTORE Target194
Figure 98 UCN Status Display - LOAD/SAVE RESTORE Target Selected194
Table 26 UCN Status Display - LOAD/SAVE RESTORE195
CONTROL STATES Target196
Figure 99 UCN Status Display - CONTROL STATES Target Selected196
Table 27 UCN Status Display - CONTROL STATES Target Selected197
AUTO CHECKPT Target198
Figure 100 UCN Status Display - AUTO CHECKPT Target Selected198
Table 28 UCN Status Display - AUTO CHECKPT Target Selected199
UCN CABLE STATUS Target200
Figure 101 UCN Status Display - UCN CABLE STATUS Target Selected200
Figure 102 UCN Status Display - NIM Node and UCN CABLE STATUS Targets Selected201
Figure 103 UCN Status Display - HPM Node and UCN CABLE STATUS Targets Selected201
Table 29 UCN CABLE STATUS Target Selected202
Figure 104 UCN Network Statistics Display204
Figure 105 UCN Network Statistics Display - UCN Node Selected204
Table 30 UCN Network Statistics Display Definitions205
Table 31 EUCN Network Statistics Display Definitions206
RUN STATES Target207
Figure 106 UCN Status Display - RUN STATES Target Selected207
Table 32 UCN Status Display - RUN STATES Target Selected208
SLOT SUMMARY Target209
Figure 107 UCN Status Display - SLOT SUMMARY Target Selected209
Figure 108 UCN Status Display - REGULATORY CONTROL POINTS Target Selected210
DETAIL STATUS Target211
System Error Journal Messages211
HPM Status Displays211
Introduction211
Figure 109 HPM Status Display211
Primary and Secondary Hpmms212
Table 33 HPM Status Display - UCN and HPM Status212
HPMM Node Number213
HPMM Operational States213
Primary HPMM Status213
Table 34 HPM Status Display - Primary HPMM Status213
Secondary HPMM Status214
40 IOP Status Boxes214
IOP Status Box Definitions214
IOP Synchronization Status214
IOP Status States214
Table 35 HPM Status Display Definitions - Secondary HPMM Status214
IOP a Status States215
Table 36 HPM Status Display - IOP a Status215
IOP B Status States216
Command Targets216
Table 37 HPM Status Display - IOP B Status216
LOAD/SAVE RESTORE Target217
Figure 110 HPM Status Display - LOAD/SAVE RESTORE Target Selected217
LOAD/SAVE RESTORE Display Targets218
Table 38 HPM Status Display - LOAD/SAVE RESTORE Target Selected218
CONTROL STATES Target219
CONTROL STATES Display Targets219
AUTO CHECKPT Target219
Table 39 HPM Status Display - CONTROL STATES Target Selected219
Figure 111 HPM Status Display - CONTROL STATES Target Selected219
AUTO CHECKPT Display Targets220
Table 40 HPM Status Display - AUTO CHECKPT Target Selected220
Figure 112 HPM Status Display - AUTO CHECKPT Target Selected220
IOL CABLE COMMANDS Target221
Figure 113 HPM Status Display - IOL CABLE COMMANDS221
IOL CABLE COMMANDS Display Targets222
Table 41 HPM Status Display - IOL CABLE COMMANDS222
RUN STATES Target223
Figure 114 HPM Status Display - RUN STATES Target Selected223
RUN STATES Display Targets224
Table 42 HPM Status Display - RUN STATES Target Selected224
SLOT SUMMARY Target225
Figure 115 HPM Status Display - SLOT SUMMARY Target Selected225
REGULATORY CONTROL POINTS Target226
Process Module Points Display Targets226
DETAIL STATUS Target226
Figure 116 HPM Status Display - REGULATORY CONTROL POINTS Target Selected226
NIM Detail Status Displays227
Selection Procedure227
NIM Driver Configuration Display227
Figure 117 NIM Driver Configuration Display227
NIM Driver Configuration Display Status228
UCN Driver Statistics (UCN STATS Target)228
Table 43 NIM Driver Configuration Display Status228
NIM and HPMM Display Differences229
Page Statistical and Status Content229
Switching Display Pages229
NIM Local UCN Statistics Display229
Figure 118 NIM Local UCN Statistics Display229
NIM Local UCN Statistics Display230
Two Pages230
Cable Noise/Silence230
Time Sync Operation230
Figure 119 NIM Local UCN Statistics Display230
Four Second Update231
HELP Target231
HPMM Detail Status Displays232
HPMM Detail Status Display Selection232
Primary HPMM Detail Status Display232
Figure 120 Primary HPMM Detail Status Display232
Secondary HPMM Detail Status Display233
Targets and Bottom Data Fields233
Figure 121 Secondary HPMM Detail Status Display233
Bottom Data Fields Defined234
Four-Second Update234
Target Comparison234
Table 44 HPMM Detail Status Display234
HPMM I/O Link Information Display235
Primary HPMM I/O Link Information Display235
Figure 122 Primary HPMM I/O Link Information Display235
Secondary HPMM I/O Link Information Display236
Four -Second Update236
Figure 123 Secondary HPMM I/O Link Information Display236
HPMM I/O Link Status237
Table 45 HPMM I/O Link Information Display237
HPMM IOM I/O Link Information Display239
Data Tables239
Figure 124 IOM I/O Link Information Display239
DSA Data Fields240
Table 46 IOM I/O Link Information Display240
HPMM Version/Revision Display241
Figure 125 HPMM Version/Revision Display241
Version and Revision Data242
Table 47 HPMM Version/Revision Display242
HPMM Control Configuration Display243
HPMM Write Lockout Control Display243
Figure 126 HPMM Write Lockout Control Display243
Control Configuration Display Information244
Table 48 HPMM Control Configuration Display244
Schedule Overrun Counters245
HPM Write Lockout Displays245
Table 49 HPMM Schedule Overrun Counters Statistics245
Figure 127 HPM Write Lockout Target245
Figure 128 HPM Write Lockout Control Display - Improper US Keylock Position246
Figure 129 HPM Write Lockout Control Help Display247
HPMM Schedule Information Display248
Figure 130 HPMM Schedule Information Display248
HPMM UCN Statistics Displays249
Table 50 Performance Statistics249
Figure 131 HPMM UCN Statistics Display250
Figure 132 HPMM UCN Statistics Display250
HPMM Maintenance Support Displays251
Figure 133 HPMM Communications Error Block Display252
Figure 134 HPMM Control Block Display253
Figure 135 HPMM Control Patches Display254
Figure 136 HPMM Communications Patches Display255
Figure 137 HPMM Node Status Information Display256
Table 51 HPMM Node Status Information Display257
Manufacturing Information Display258
Figure 138 Manufacturing Information Display258
HPMM Soft Failure Displays259
Figure 139 HPMM Soft Failure Display259
Figure 140 HPMM Soft Failure Display - 00-39260
Figure 141 HPMM Soft Failure Display - 40-79260
Figure 142 HPMM Soft Failure Display - 80-95261
IOP Detail Status Displays262
Overview262
Top Portion of Display262
Primary and Secondary IOP Displays262
Figure 143 HLAI IOP Detail Status Display262
Bottom of Display263
IOP Configuration263
Table 52 IOP Detail Status Display - IOP Configuration263
I/O Link Cable Status and Statistics264
Status Messages264
Table 53 IOP Detail Status Display - I/O Link Cable Status/Statistics264
Table 54 IOP Detail Status Display - I/O Link Cable Status Messages264
Loss of Communications265
4-Second Data Update265
IOP Box Soft Failures Displays265
Figure 144 IOP Box Soft Failures Display266
Figure 145 IOP Box Soft Failures Display267
Figure 146 IOP Box Soft Failures Display267
Figure 147 IOP Box Soft Failures Display268
Figure 148 IOP Box Soft Failures Display268
Figure 149 IOP Box Soft Failures Display269
IOP Slot Soft Failures Displays270
Figure 150 IOP Slot Soft Failures Display271
Figure 151 IOP Slot Soft Failures Display271
Figure 152 IOP Slot Soft Failures Display271
Figure 153 IOP Slot Soft Failures Display272
IOP Slots with Soft Failures Display273
HLAI IOP Detail Status Display273
Figure 154 IOP Slots with Soft Failures Display273
Figure 155 High Level Analog Input IOP Detail Status Display - ENABLE CALIBRATN Target Selected274
LLAI IOP Detail Status Display275
Figure 156 High Level Analog Input IOP Detail Status Display - DISABLE CALIBRATN Target Selected275
Figure 157 Low Level Analog Input IOP Detail Status Display -ENABLE CALIBRATN and ENABLE RJ CALIBR Targets275
Figure 158 Low Level Analog Input IOP Detail Status Display - DISABLE CALIBRATN Target Selected277
Figure 159 Low Level Analog Input IOP Detail Status Display - DISABLE RJ CALIBR Target Selected278
Figure 160 Low Level Analog Input IOP Detail Status Display279
AO IOP Detail Status Display280
Table 55 Low Level Analog Input IOP Detail Status Display280
Figure 161 8-Channel -Analog Output IOP Detail Status Display281
Figure 162 16-Channel Analog Output IOP Detail Status Display282
Figure 163 Analog Output IOP Detail Status Display - ENABLE CALIBRATN Target Selected283
Llmux IOP Detail Status Display284
Figure 164 Analog Output IOP Detail Status Display - DISABLE CALIBRATN Target Selected284
Figure 165 Low Level Multiplexer IOP Detail Status Display-ENABLE CAL on Target Selected285
Figure 166 Low Level Multiplexer IOP Detail Status Display-DISABLE CALIBRATN Target Selected285
RHMUX IOP Detail Status Display286
Figure 167 Low Level Multiplexer IOP Detail Status Display286
Figure 168 Remote Hardened Multiplexer IOP Detail Status Display - ENABLE CAL on Target Selected287
Figure 169 Remote Hardened Multiplexer IOP Detail Status Display - DISABLE CALIBRATN Target Selected288
DI IOP Detail Status Display289
Figure 170 Remote Hardened Multiplexer IOP Detail Status Display289
DO IOP Detail Status Display290
Figure 171 Digital Input IOP Detail Status Display290
Figure 172 16-Channel Digital Output IOP Detail Status Display291
STI/STIM IOP Detail Status Display292
Figure 173 32-Channel Digital Output IOP Detail Status Display292
PI IOP Detail Status Display293
Figure 174 Smart Transmitter Interface IOP Detail Status Display293
SDI IOP Detail Status Display294
Figure 175 Pulse Input IOP Detail Status Display294
SI IOP Detail Status Display295
Figure 176 Serial Device Interface IOP Detail Status Display295
DISOE IOP Detail Status Display296
Figure 177 Serial Interface IOP Detail Status Display296
Figure 178 Digital Input Sequence of Events IOP Detail Status Display297
Figure 179 IOP PI Loading Information Display298
Table 56 IOP PI Loading Information Display299
Fault Isolation301
Overview301
Purpose301
Release 500 Software Displays301
Failure Types301
Two Types of Failures301
Hard Failure301
Soft Failure301
Hard and Soft Failures301
HPM Failure301
HPMM Hard Failure302
HPM Partial Failure302
HPMM Soft Failure302
IOP Hard Failure302
IOP Soft Failure302
Fault Isolation Concepts303
Introduction303
Troubleshooting Flowcharts303
Recommendations for Operators and Service Technicians304
Troubleshooting Table Usage304
Troubleshooting Flow Chart306
Figure 180 HPM Fault Isolation Flowchart (Sheet 1 of 6)306
Figure 181 HPM Fault Isolation Flowchart (Sheet 2 of 6)307
Figure 182 HPM Fault Isolation Flowchart (Sheet 3 of 6)308
Figure 183 HPM Fault Isolation Flowchart (Sheet 4 of 6)309
Figure 184 HPM Fault Isolation Flowchart (Sheet 5 of 6)310
Figure 185 HPM Fault Isolation Flowchart (Sheet 6 of 6)311
HPMM Corrective Actions312
Table 57 HPMM Corrective Actions312
I/O Link Overruns314
I/O Link Overruns Corrective Actions315
Comm/Control Hard Failure Codes315
Table 58 Communications and Control Processor Hard Failure Codes315
HPMM Soft Failure Codes335
Comm/Control Soft Failure Error Codes337
Table 59 Comm/Control Soft Failure Error Codes337
I/O Link Processor Hard Failure Error Codes340
Table 60 I/O Link Hard Failure Error Codes340
IOP Hard Failure Error Codes341
Table 61 IOP Hard Failure Error Codes341
IOP Box Soft Failure Error Codes343
Table 62 IOP Box Soft Failure Error Codes343
IOP Slot Soft Failure Error Codes348
Table 63 IOP Slot Soft Failure Error Codes348
Additional Troubleshooting for EUCN Nodes349
Smart Transmitter Interface350
Introduction350
STI IOP and FTA Faults350
Two Wire Link or Smart Transmitter Faults351
FTA Redundancy Indicators351
Introduction351
AO FTA Redundancy Indicator351
HLAI FTA Redundancy Indicator351
Redundant Analog Output IOP Failure Diagnosis351
Considerations352
Avoid Removing IOP a352
IOP a Preference352
Replacing the FTA Switching Module352
Switch to IOP a When a Soft Failure Occurs352
Consider Use of an AO Standby Manual Device352
OK/CNF [S] Status353
Replacing the Switching Module353
[S] CNF/OK Status353
Best Solution When Replacing Switching Module353
Switching Module Replacement Procedure354
IOP B Should be Secondary354
Battery Backup Exhaustion354
Introduction354
Loss of 24 VDC354
Multiple Battery Backup354
US Response to 48 VDC Battery Failure354
HPMM Card and Module Indicators355
Application of Power355
Status Indicators and Alphanumeric Display355
HPM UCN Interface Module355
Indicator Functionality355
Table 64 HPMM Card and Module Indicators355
High-Performance Comm/Control Card Status Indicator356
High-Performance I/O Link Card Status Indicator356
HPM UCN Interface Module Transmit Indicator357
Power and Status Indicators357
HPMM Fuse357
UCN Interface Module Fuse357
HPMM Card Extractors357
HPMM Alphanumeric Display358
Introduction358
Detailed Display Switch358
Rapidly Changing of Display Contents358
Alphanumeric Display Format358
Table 65 Alphanumeric Display Formats359
Table 66 EHPM Alphanumeric Display Formats361
Notification Displays363
Cold HPMM Startup Display Sequences363
Table 67 User Notification Message Formats363
Table 68 Alphanumeric Display for a Normal Startup Sequence363
Table 69 Alphanumeric Display for Startup/Factory Test Mode Sequence364
HPMM Load Display Sequence365
Table 70 Alphanumeric Display for HPMM Cold Startup Failure Sequence365
Table 71 Alphanumeric Display for Load Sequence365
Nonredundant HPM Failure Sequences (after Load)366
Table 72 Communications/I/O Link Processor Failure Display Sequence366
Table 73 Control Processor Failure Display Sequence367
HPMM RAM Retention Startup Sequence368
Table 74 RAM Retention Startup Display Sequence368
HPMM Redundancy Display Sequences369
Table 75 Alphanumeric Display for HPMM Swapping Sequence (Detailed Display Mode)369
Table 76 Alphanumeric Display for HPMM Swapping Sequence (Non-Detailed Display Mode)370
Table 77 Alphanumeric Display for Failover HPMM Swapping Sequence (Detailed Display Mode)370
HPMM Alphanumeric Display Blanking371
Table 78 Alphanumeric Display for Failover HPMM Swapping Sequence (Non-Detailed Display Mode)371
HPMM Diagnostic Tests List372
Table 79 HPMM Diagnostic Test List372
4.10 HPM Alternate Private Path377
Overview377
Equipment and Revision Requirements378
HPPM Redundancy Restoration Procedure378
4.11 I/O Card Indicators380
Loss of Power380
Overview380
Indicator Functionality380
Table 80 IOP Card Indicators380
Multifunctional Status Indicator381
4.12 FTA Indicators381
Introduction381
FTA Indicator Functions381
Table 81 IOP Multicolor Status Indicator381
Table 82 FTA Indicators381
4.13 Power System Indicators382
Standard Power System382
Figure 186 Standard Power System Indicators382
Figure 187 Standard Power System Annunciator Contact Connections384
AC Only Power System385
4.14 Power System Voltage Checks385
Introduction385
Standard Power System386
Table 83 Standard Power System Voltage Test Points386
Figure 188 Power System Power Output Connector Pin Assignments386
Figure 189 Power Supply Module Test Points and Indicators387
Figure 190 Power System AC Wiring387
AC Only Power System388
Table 84 AC Only Power System Voltage Test Points388
Ucn Exerciser391
Overview391
Purpose391
Applications391
Two Part Test391
Request Data Response (RDR) Test392
Introduction392
RDR Protocol392
Figure 191 RDR Test Configuration392
Triangulation Test393
Introduction393
Timeout Policy393
Figure 192 Triangulation Test393
5.5 Test Operation394
UCN Exerciser Operation394
Starting the UCN Exerciser394
PAGE Target394
HELP Target394
UCN Exerciser Overview Display394
Figure 193 UCN Exerciser Overview Display394
Figure 194 UCN Exerciser Overview Display394
UCN Exerciser Help Display395
Connection Test Summary Display395
Figure 195 UCN Exerciser Help Display395
Figure 196 Connection Test Summary Display395
Connection Test Summary Display397
UCN Exerciser Test Procedure397
Figure 197 Connect Test Summary Display397
Analyzing Results399
Connect Test Detail Display399
Number of Attempt Errors399
Problem Correction399
Figure 198 Connection Test Detail Display399
Removal and Replacement401
Overview401
Introduction401
Electrostatic Discharge Protection401
ESD Guidelines for HPMM and IOP Cards402
Static Discharge Effects402
ESD Kit402
Building a Static Discharge Probe402
Figure 199 Cabinet ESD Wriststrap Connection402
ESD Prevention Rules403
HPMM and IOP Cards404
Removal and Replacement404
HPMM and IOP Card Removal and Replacement404
HPM UCN Interface Module Removal and Replacement404
Tightening the Knurled Screw405
HPM UCN Interface Module405
Figure 200 HPM UCN Interface Module Installation405
EHPM FTE Module Installation406
Standby Manual Device Overview407
Introduction407
No External Power Source Option407
Standby Manual Device Connections407
DO Standby Manual Device Connection408
Figure 201 Digital Output Manual Device Interconnection408
Device Interchangeability409
DIN to Phone Connector Adaptor Cable409
Board Revision Level409
AO Standby Manual Device Operation409
Purpose409
Two Models409
Original Analog Output Standby Manual Device410
Figure 202 Original Analog Output Standby Manual Device (Two Per Device)410
Compact Analog Output Standby Manual Device412
Figure 203 Compact Analog Output Standby Manual Device412
DO Standby Manual Device Operation414
Purpose414
Secondary Function414
Mounting Locations414
Connection415
Output Control Switches Disablement415
Switch Activation415
Figure 204 Model MU-SMDC02 Portable Digital Output Standby Manual Device415
Standby Manual Device Control Procedure416
Figure 205 Digital Standby Manual Device Panel416
Normal IOP Control Procedure418
HPMM or IOP Card Case Replacement419
Handling and Installing HPM Components419
Disassembly/Assembly Procedure419
Card Case Illustration420
Figure 206 Replacing HPMM or IOP Card Case420
IOP to FTA Cable Replacement421
Nonredundant IOP Cable Replacement421
Redundant IOP Cable Replacement421
FTA Replacement421
Replacement Procedure423
FTA Module and Relay Replacement424
Replacement Procedure424
LLAI Module Replacement424
AO Redundancy Switching Module Replacement424
SDI/SI Module and Fuse Replacement424
Galvanic Isolation Module Replacement424
6.10 Card File Replacement425
Replacement Procedure425
6.11 Power System425
Introduction425
6.12 CMOS Battery Replacement425
Nicad Batteries425
Alkaline Batteries426
Replacement Procedure426
6.13 48 V Backup Battery Replacement426
Battery Operational and Service Life426
Battery Performance426
48 V Battery Pack End-Of-Life426
48 V Battery Pack Service Life427
Battery Charge Voltage Check Procedure427
End of Battery Pack Life Check428
Battery Pack Removal429
Battery Pack Installation429
6.14 Power Supply Module Replacement430
Introduction430
Replacement Procedure430
6.15 CMOS Backup Assembly Replacement431
Introduction431
Replacement Procedure431
6.16 Cabinet431
Cabinet Side Panels (Markhon)431
Cabinet Side Panels (Rittal)431
6.17 I/O Link Extender Optical Coupler Module Replacement432
Introduction432
Replacement Procedures432
Non-CE Compliant Replacement Procedure432
CE Compliant Replacement Procedure433
Coupler Adapter Kit434
Figure 207 I/O Link Extender Fiber Optic Coupler Module Adapter Kit Pictorial434
Iop Calibration Procedures435
Overview435
Introduction435
No Manual Adjustments435
LLAI, HLAI, and AO IOP Calibration435
Common Calibration Procedures435
IOP or FTA Substitution435
Equipment Required436
Precision Equipment Is a Necessity436
You will Need Precision Equipment to Accurately Recalibrate These Subsystems436
Equipment Requirements436
Table 85 Typical Precision Test Equipment436
LLAI IOP Calibration Procedure437
Caution437
Seven Ranges437
Calibration Affects Eight Slots437
Range Type Selection437
Select RTD or TC Calibration437
Performing Calibration Sequences437
Calibration Procedure438
Figure 208 Zero Calibration Circuit - TC and All Linear Zero Circuits438
Figure 209 Zero Calibration Circuit - RTD Zerocu: 10 Ohm, Pt: 100 Ohm, Ni: 120 Ohm439
Figure 210 LLAI FTA Showing DS1 Status Indicator and Calibration Pads440
Figure 211 Full Scale Calibration Circuit - TC and All Linear Full Scale Circuits441
Figure 212 RTD Full Scale Calibration Circuit Cu: 10 Ohm, Pt: 100 Ohm, Ni: 120 Ohm442
RJ Calibration Circuit for RJ Zero443
Figure 213 RJ Calibration Circuit - RJ Zero443
RJ Calibration Circuit for RJ Full Scale444
Figure 214 RJ Calibration Circuit - RJ Full Scale444
Nonredundant HLAI IOP Calibration Procedure445
Caution445
Introduction445
Galvanic Isolation FTA Connection Points445
Calibration Terminals445
Table 86 Galvanically Isolated HLAI Calibration Connector Pins445
Galvanic Isolation HLAI Calibration Tool446
Calibration Procedure446
Figure 215 Galvanic Isolation HLAI Calibration Tool (51201450)446
Figure 216 Nonredundant HLAI Calibration Connections447
Redundant HLAI IOP Calibration Procedure448
Caution448
Simultaneous IOP Calibration448
Calibration Connections449
Figure 217 Redundant HLAI Calibration Connections449
Nonredundant AO IOP Calibration Procedure450
Calibration Procedure450
Redundant AO IOP Calibration Procedure451
Simultaneous IOP Calibration451
Figure 218 Nonredundant AO Calibration FTA Connections451
Calibration Connections452
Figure 219 Redundant Analog Output Calibration Connections452
Llmux IOP Calibration Procedure453
Caution453
Introduction453
Calibration Procedure453
Llmux FTA Calibration Connections454
7.10 RHMUX IOP Calibration Procedure454
Introduction454
Figure 220 Llmux FTA Calibration Connections454
Calibration Method455
Field Calibration Overview455
Calibration Procedure456
Calibration Failure456
7.11 Thermocouple Input Accuracy Verification457
Introduction457
Accuracy Verification Procedure457
Periodic Redundancy Tests459
Overview459
Introduction459
HPMM Redundancy459
HPMM Swap Verification460
IOP Redundancy460
Introduction460
IOP Redundancy Terminology460
IOP Redundancy Test Procedure460
Redundant 8-Channel Analog Output Iops461
Introduction461
Hardware Identification461
Status Check462
Test Procedure462
Power Cable Redundancy463
Introduction463
Test Procedure463
Power Supply Module Redundancy464
Power System Redundancy Introduction464
Power System Redundancy Test Procedure464
Spare Parts465
Overview465
Introduction465
Periodic Maintenance Parts465
Periodic Maintenance Parts List465
Table 87 HPM Periodic Maintenance Parts465
ORU Parts List467
Table 88 Non-Conformally Coated HPM ORU Parts List467
Conformally Coated ORU Parts List483
Table 89 Conformally Coated HPM ORU Parts List483
UCN/EUCN Parts493
UCN Parts List493
Table 90 UCN Parts List493
EUCN Parts List495

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