Fail Safe Control: Service Manual

Fail Safe Control
Service Manual
Revision 03
03/2000
FS99-504
Copyright, Notices and Trademarks

2000 Honeywell Safety Management Systems B.V.
Revision 03 (03/2000)
While this information is presented in good faith and believed to be accurate, Honeywell Safety Management Systems B.V. disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer. In no event is Honeywell Safety Management Systems B.V. liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.
TotalPlant, TDC 3000 and Universal Control Network are U.S. registered trademarks of Honeywell International Inc. PlantScape is a trademark of Honeywell International Inc. FSC is a trademark of Honeywell Safety Management Systems B.V. Other brands or product names are trademarks of their respective holders.
No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Honeywell Safety Management Systems B.V.
TABLE OF CONTENTS
Section 1 Introduction
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Section overview.....................................................................................................................1 Scope of this document ..........................................................................................................1 Terminology ............................................................................................................................2 Competence of people............................................................................................................3 Precautions when working on FSC cabinets ..........................................................................4 Hardware requirements ..........................................................................................................6 Tools required .........................................................................................................................7 Reference documents.............................................................................................................8
Section 2 Installation Guide

2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 Section overview...................................................................................................................11 Environmental conditions......................................................................................................12 Transportation conditions......................................................................................................13 Storage conditions ................................................................................................................14 Operating conditions .............................................................................................................15 FSC general cabinet layout...................................................................................................16 Unpacking, moving and placement.......................................................................................19 Unpacking the equipment .....................................................................................................19 Moving preparations .............................................................................................................23 Moving an FSC cabinet.........................................................................................................26 Interconnecting FSC cabinets...............................................................................................33 After placement.....................................................................................................................34
Section 3 Connection of External Cables

3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 Section overview...................................................................................................................37 Interconnection wiring ...........................................................................................................38 Separation and routing of cables and wiring.........................................................................39 Earth/grounding cables .........................................................................................................40 Introduction ...........................................................................................................................40 Safety earth/ground ..............................................................................................................41 Instrument earth/ground........................................................................................................41 Ex(i) earth/ground .................................................................................................................41 Power/feeder cables .............................................................................................................42 Introduction ...........................................................................................................................42 Supply voltages.....................................................................................................................42 AC/DC power supply units ....................................................................................................43 Connecting AC power/feeder cables ....................................................................................43 DC power ..............................................................................................................................45 Connecting DC power/feeder cables ....................................................................................45
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TABLE OF CONTENTS (continued)

3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.7 3.7.1 3.7.2 3.7.3 3.7.4 Field cables ...........................................................................................................................48 Introduction ...........................................................................................................................48 I/O module wiring using FTA-T devices ................................................................................49 I/O module wiring using FTA-E .............................................................................................52 I/O module wiring using terminals.........................................................................................55 I/O module wiring using third-party devices ..........................................................................58 Communication cables..........................................................................................................61 Introduction ...........................................................................................................................61 Connecting fiber optic cables................................................................................................62 Connecting trunk cables to taps............................................................................................66 Connecting other communication cables ..............................................................................66
Section 4 Power-Up of the FSC Cabinet

4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 Section overview ...................................................................................................................69 Checks prior to power-up......................................................................................................70 Checking all signal wiring......................................................................................................70 Checking all incoming power ................................................................................................70 Checking AC power ..............................................................................................................70 Checking DC power ..............................................................................................................72 Performing the power-up ......................................................................................................73 Powering up a redundant system .........................................................................................73 Powering up a single system ................................................................................................73 Troubleshooting ....................................................................................................................73 Activities after power-up........................................................................................................74
Section 5 Site Acceptance Test

5.1 5.2 5.3 5.4 5.5 Section overview ...................................................................................................................75 SAT definition and objective .................................................................................................76 Involved parties .....................................................................................................................77 Documentation required........................................................................................................77 Contents of the SAT document.............................................................................................79
Section 6 General Maintenance Considerations

6.1 6.2 6.3 6.4 6.5 6.6 Section overview ...................................................................................................................81 Types of maintenance...........................................................................................................82 Corrective maintenance ........................................................................................................83 Actions before maintenance, service and modification.........................................................84 Actions during maintenance, service and modification.........................................................86 Actions after maintenance, service and modification............................................................87
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Section 7 Preventive Maintenance
7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.4.8 7.4.9 7.4.10 7.4.11 7.4.12 7.4.13 Section overview...................................................................................................................89 Preventive maintenance overview ........................................................................................90 Three-monthly preventive maintenance ...............................................................................91 Overview ...............................................................................................................................91 Checking the voltages to the Central Part ............................................................................91 Checking the temperatures in the Central Part.....................................................................96 Checking air flow obstruction ................................................................................................98 Checking the correct operation of the fans ...........................................................................98 Checking for earth faults .......................................................................................................99 Checking the loop status of signals ....................................................................................101 Checking the forced status of signals .................................................................................103 Checking for paint damage .................................................................................................104 Checking the availability of spare parts ..............................................................................104 Checking the system diagnostics .......................................................................................105 Checking the backup of the application files.......................................................................106 Preventive maintenance during every power-down............................................................107 Overview .............................................................................................................................107 Checking all DC voltages....................................................................................................108 Checking the power distribution fuses ................................................................................109 Checking the AC voltages...................................................................................................110 Checking the correct operation of the PSUs.......................................................................111 Checking for dust concentration .........................................................................................112 Replacing all dust filters ......................................................................................................112 Checking the fasteners on the power distribution rails .......................................................113 Checking all cable clamps ..................................................................................................113 Checking all shield connections..........................................................................................114 Checking all earth/ground connections...............................................................................115 Testing all hardware I/O......................................................................................................116 Testing all communication links to external devices ...........................................................118
Section 8 Troubleshooting and Fault-Finding

8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.4 Section overview.................................................................................................................121 Notification of alarms and errors .........................................................................................122 Retrieving diagnostic information from the FSC system.....................................................123 Visible and/or audible alarms..............................................................................................123 FSC Navigator software......................................................................................................123 Diagnostic and Battery Module (DBM) ...............................................................................125 Sequence-of-Event (SOE) station ......................................................................................125 Acting on the information retrieved .....................................................................................127
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Section 9 Service and/or Modification to the FSC Cabinet
9.1 9.2 9.2.1 9.2.2 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.4.10 9.4.11 9.4.12 Section overview .................................................................................................................129 Service and modification overview......................................................................................130 Important considerations.....................................................................................................130 On-line modification ............................................................................................................131 Hardware service and/or modification to the FSC cabinet..................................................132 Introduction .........................................................................................................................132 Adding a communication module........................................................................................132 Adding an I/O rack ..............................................................................................................133 Adding I/O modules.............................................................................................................133 Adding wiring to existing circuit breaker .............................................................................134 Changing converter modules ..............................................................................................135 Calibrating transmitters .......................................................................................................138 Key coding ..........................................................................................................................138 Updating documentation .....................................................................................................139 Software service and/or modification to the FSC cabinet ...................................................140 Introduction .........................................................................................................................140 Verifying the application files ..............................................................................................140 Backing up the application files...........................................................................................141 Adding/changing FLDs........................................................................................................142 Renumbering FLDs .............................................................................................................143 Adding/changing timers ......................................................................................................143 Changing counters ..............................................................................................................143 Loopback of sheet references.............................................................................................144 EPROM/RAM size...............................................................................................................146 Square root of a negative value ..........................................................................................146 Divide by zero .....................................................................................................................146 Range-checking errors........................................................................................................147
Section 10 Training Courses

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 Section overview .................................................................................................................149 Training overview ................................................................................................................150 Fail Safe Controller Managers Overview course (4501).....................................................151 Introduction to IEC 61508 course (4504) ............................................................................152 Fail Safe Controller Implementation course (4508) ............................................................153 Fail Safe Controller Maintenance course (4505) ................................................................154 Fail Safe Controller On-Line Modification course (4502)....................................................155 Fail Safe Controller Advanced course (4512).....................................................................156 Fail Safe Controller Total Package course .........................................................................157 Customized training courses...............................................................................................157
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Section 11 Decommissioning
11.1 11.2 11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 Section overview.................................................................................................................159 Decommissioning overview ................................................................................................160 Decommissioning procedure ..............................................................................................161 Checking system operation.................................................................................................161 Powering down the FSC cabinet ........................................................................................161 Disconnecting all cables .....................................................................................................162 Removing all recyclable items ............................................................................................165 Removing all batteries ........................................................................................................166 Removing the FSC cabinet .................................................................................................166
Appendix A Plinth Layouts

A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.9 A.10 A.11 Section overview.................................................................................................................169 Introduction .........................................................................................................................170 No plinth for one PS 4806 cabinet ......................................................................................171 Plinth for one PS 4806 cabinet ...........................................................................................172 Plinth for two PS 4806 cabinets ..........................................................................................173 Plinth for three PS 4806 cabinets .......................................................................................174 No plinth for one PS 4808 cabinet ......................................................................................175 Plinth for one PS 4808 cabinet ...........................................................................................176 Plinth for two PS 4808 cabinets ..........................................................................................177 Plinth for three PS 4808 cabinets .......................................................................................178 Plinth for four PS 4808 cabinets .........................................................................................179
Appendix B Stopping / Powering Down the FSC System

B.1 B.2 B.3 B.4 B.5 B.6 B.7 Section overview.................................................................................................................181 Central Part configuration ...................................................................................................182 Stopping one CP of an FSC system with redundant CPs ..................................................183 Stopping both CPs of an FSC system with redundant CPs................................................185 Powering down an FSC system with redundant CPs .........................................................188 Stopping the CP of an FSC system with a single CP .........................................................192 Powering down an FSC system with a single CP...............................................................194

Appendix C Starting Up / Powering Up the FSC System
C.1 C.2 C.3 C.4 C.5 C.6 C.7 Section overview .................................................................................................................197 Central Part configuration ...................................................................................................198 Starting one CP of an FSC system with redundant CPs ....................................................199 Starting both CPs of an FSC system with redundant CPs..................................................203 Powering up an FSC system with redundant CPs..............................................................209 Starting the CP of an FSC system with a single CP ...........................................................215 Powering up an FSC system with a single CP ...................................................................218
Appendix D Alarm/Error Messages and Solutions

D.1 D.2 D.3 D.4 D.5 D.6 D.7 D.8 D.9 D.10 Section overview .................................................................................................................223 General messages ..............................................................................................................224 Analog input module 10102/x/x...........................................................................................225 Analog input module 10105/2/1 ..........................................................................................226 Analog output module 10205/2/1 ........................................................................................227 Communication errors with the FSC user station ...............................................................228 Output short circuit ..............................................................................................................229 Download not successful ....................................................................................................230 Process trip during an on-line modification.........................................................................231 Calculation errors ................................................................................................................232
Appendix E Checklists
E.1 E.2 E.3 E.4 Section overview .................................................................................................................235 Preventive maintenance overview ......................................................................................236 Checklist for three-monthly maintenance ...........................................................................238 Checklist for maintenance during power-down...................................................................241
Appendix F Using Ferrites

F.1 F.2 F.3 F.4 Section overview .................................................................................................................245 Using ferrites .......................................................................................................................246 Ferrites on AC power/feeder cables ...................................................................................250 Ferrites on DC power/feeder cables ...................................................................................251
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Appendix G Repair Handling and Ordering of Emergency Spare Parts
G.1 G.2 G.3 G.4 Section overview.................................................................................................................253 Terminology ........................................................................................................................254 Handling of defective products/parts ..................................................................................255 Ordering of emergency replacements ................................................................................257
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Figures
Figure 1-1 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 7-1 Figure 7-2 Figure 7-3 Figure 7-4 Figure 7-5 Figure 8-1 Figure 9-1 Figure A-1 Figure A-2 Figure A-3 Figure A-4 Figure A-5 Figure A-6 Figure A-7 Figure A-8 Figure A-9 Figure F-1 Figure F-2 Figure F-3 Figure F-4 ESD wrist-strap connected to ESD bonding point ..........................................................4 Placement of an FSC cabinet onto lumber...................................................................27 Placement using a mobile lifter.....................................................................................29 Lifting equipment by mobile lifter or crane....................................................................30 Moving the FSC cabinet using the roller method..........................................................31 Eyebolt crane method...................................................................................................32 Typical routing of internal wiring between I/O modules and FTA-T via SIC-Cs ...........49 Bonding of shielded cables (FTA-T) .............................................................................51 Typical routing of internal wiring between I/O modules and FTA-E via SIC-Cs ...........52 Bonding of shielded cables (FTA-E) .............................................................................54 Typical layout of a SIC-P cable.....................................................................................55 Bonding of shielded cables (terminals).........................................................................57 Status of Diagnostic and Battery Module (DBM) ..........................................................94 Viewing the I/O loop status .........................................................................................102 Listing all forces in the system....................................................................................103 Checking the system diagnostics ...............................................................................105 Bonding of shielded cables.........................................................................................114 Viewing the extended diagnostic information .............................................................124 Off-sheet references and loopbacks...........................................................................144 No plinth for one Rittal PS 4806 cabinet.....................................................................171 Plinth for one Rittal PS 4806 cabinet ..........................................................................172 Plinth for two Rittal PS 4806 cabinets ........................................................................173 Plinth for three Rittal PS 4806 cabinets ......................................................................174 No plinth for one Rittal PS 4808 cabinet.....................................................................175 Plinth for one Rittal PS 4808 cabinet ..........................................................................176 Plinth for two Rittal PS 4808 cabinets ........................................................................177 Plinth for three Rittal PS 4808 cabinets ......................................................................178 Plinth for four Rittal PS 4808 cabinets ........................................................................179 Ferrite types ................................................................................................................246 Ferrite layout ...............................................................................................................247 Ferrites on AC power/feeder cables ...........................................................................250 Ferrites on DC power/feeder cables ...........................................................................251
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Tables
Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 3-1 Table 9-1 Table 9-2 Table D-1 Table D-2 Table D-3 Table D-4 Table D-5 Table D-6 Table D-7 Table D-8 Table D-9 Table E-1 Table E-2 Table F-1 Table F-2 Table F-3 Move preparation checklist ...........................................................................................24 Preparing the electronics room.....................................................................................25 Fork lift considerations..................................................................................................27 Mobile lift considerations ..............................................................................................28 Roller method considerations .......................................................................................31 Routing of cables carrying different voltages................................................................39 Conversion table.........................................................................................................147 FSC register types ......................................................................................................147 General, non module-specific messages ...................................................................224 Messages related to 10102/x/x analog input modules ...............................................225 Messages related to 10105/2/1 analog input module.................................................226 Messages related to 10205/2/1 analog output module ..............................................227 No communication with the FSC system....................................................................228 Output short circuit......................................................................................................229 Download not successful ............................................................................................230 Process trip .................................................................................................................231 Calculation errors........................................................................................................232 Three-monthly maintenance checklist ........................................................................238 Power-down maintenance checklist ...........................................................................241 Wrth and Kitagawa ferrites and their characteristics ................................................246 Ferrite selection (example) .........................................................................................248 Ferrite selection table .................................................................................................249
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Abbreviations
A/D ............................................................................................................................................. Analog/digital AC ...................................................................................................................................... Alternating current AI..................................................................................................................................................Analog input AK ................................................................................................ Anforderungsklasse (= requirement class) AO............................................................................................................................................. Analog output AWG .............................................................................................................................. American Wire Gage BCD .............................................................................................................................. Binary coded decimal c .........................................................................................................................................................common CE ............................................................................................................................. Conformit Europenne Ch ...................................................................................................................................................... Channel COM ...................................................................................................................................... Communication COSI ....................................................................................................................................Crimp-on snap-in CP ................................................................................................................................................ Central Part CPU ............................................................................................................................. Central processor unit D/A .............................................................................................................................................Digital/analog DBM ................................................................................................................Diagnostic and battery module DC.............................................................................................................................................. Direct current DCD ...................................................................................................................................Data carrier detect DCF .........................................................................................................................Digital Coded Frequency DCS ....................................................................................................................... Distributed control system DI ..................................................................................................................................................Digital input DIL .................................................................................................................................................Dual in-line DIN............................................................................................................................ Deutsche Industrienorm DoC.........................................................................................................................Declaration of Conformity DO ..............................................................................................................................................Digital output DOS ............................................................................................................................. Disk operating system DSR ......................................................................................................................................... Data set ready DTR ................................................................................................................................. Data terminal ready EEA........................................................................................................................ European Economic Area EEPROM ..................................................................Electrically erasable programmable read-only memory ELD ............................................................................................................................. Earth leakage detector EMC ..................................................................................................................Electromagnetic compatibility EN ................................................................................................... Europische Norm (European standard) EPROM.......................................................................................Erasable programmable read-only memory ESD............................................................................................................................. Electrostatic discharge ESD...............................................................................................................................Emergency shutdown EU ......................................................................................................................................... European Union ext. ......................................................................................................................................................external F.......................................................................................................................................................... Fuse(d) FAT ..........................................................................................................................Factory Acceptance Test FF .......................................................................................................................................................Flip-flop FLDs ....................................................................................................................Functional Logic Diagrams FM............................................................................................................................................Factory Mutual FS ......................................................................................................................................................Fail-safe FSC.......................................................................................................................................Fail Safe Control FSC-DS ................................................................................................................ FSC Development System FSC-SM .........................................................................................................................FSC Safety Manager FSC-SMM ......................................................................................................... FSC Safety Manager Module FTA .......................................................................................................................Field termination assembly GND.....................................................................................................................................................Ground
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Table of Contents
Abbreviations (continued)
HBD ............................................................................................................................... Horizontal bus driver HE..................................................................................................................................... Hheneinheit (= U) HF .......................................................................................................................................... High Frequency HP................................................................................................................................Horizontal pitch (= TE) HSMS .............................................................................................Honeywell Safety Management Systems HW ................................................................................................................................................... Hardware H x W x D .................................................................................................................... Height x width x depth I/O .................................................................................................................................................Input/output IC .......................................................................................................................................... Integrated circuit IEC............................................................................................... International Electrotechnical Commission int. ........................................................................................................................................................internal IP ........................................................................................................................................ Ingress protection J ...........................................................................................................................................................Jumper LED.................................................................................................................................. Light-emitting diode LSB ................................................................................................................................... Least significant bit MEM ...................................................................................................................................................Memory MUX............................................................................................................................................... Multiplexer n/a............................................................................................................................................. not applicable NC.......................................................................................................................................... Normally closed nc .............................................................................................................................................. not connected NFS............................................................................................................................................. Non fail-safe NO ........................................................................................................................................... Normally open NTC .............................................................................................................Negative temperature coefficient NVRAM.................................................................................................Non-volatile random-access memory P/N...............................................................................................................................................Part number PCB .................................................................................................................................Printed circuit board PSD ........................................................................................................................ Power supply distribution PSU .................................................................................................................................... Power supply unit R ................................................................................................................................... Resistance / Resistor RAM........................................................................................................................ Random-access memory RTS....................................................................................................................................... Request to send SBD ......................................................................................................................................Single bus driver S-Bus ..............................................................................................................................................Single bus SER .................................................................................................................. Sequence-of-event recording SAT............................................................................................................................... Site Acceptance Test SIC................................................................................................................... System interconnection cable SIL .................................................................................................................................. Safety integrity level SM ......................................................................................................................................... Safety Manager SMM ......................................................................................................................... Safety Manager Module SMOD ...................................................................................................... Second Means Of De-energization SOE .................................................................................................................................Sequence of events STP................................................................................................................................ Shielded twisted pair SW .................................................................................................................................................... Software TE ........................................................................................................................................Teileinheit (= HP) TIB ...................................................................................................................... Transformer isolated barrier TPS................................................................................................................................. TotalPlant Solutions TTL ......................................................................................................................... Transistor-transistor logic TTY ....................................................................................................................................................Teletype TV........................................................................................................... Technischer berwachungsverein
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Abbreviations (continued)
U ....................................................................................................................................................Unit (= HE) UCN ...................................................................................................................... Universal Control Network UL .......................................................................................................................... Underwriters Laboratories UV ....................................................................................................................................................Ultraviolet Vac.............................................................................................................................. Volt alternating current VBD.....................................................................................................................................Vertical bus driver V-Bus ............................................................................................................................................Vertical bus Vdc...................................................................................................................................... Volt direct current WD.................................................................................................................................................. Watchdog WDG ............................................................................................................................................... Watchdog WDR .................................................................................................................................Watchdog repeater ZIF ................................................................................................................................... Zero insertion force
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REFERENCES
FSC Documentation:
Publication Title FSC Safety Manual R5xx FSC Software Manual R5xx FSC Hardware Manual Publication Number FS90-5xx* FS80-5xx* FS02-500
* '5xx' is the release number. For example, the Software Manual for FSC R510 is referenced as FS80-510, and the update for FSC R520 as FS80-520.
FSC-SM Documentation:
Publication Title FSC Safety Manager Installation Guide FSC Safety Manager Implementation Guidelines FSC Safety Manager Control Functions FSC Safety Manager Parameter Reference Dictionary FSC Safety Manager Configuration Forms FSC Safety Manager Service Manual Publication Number FS20-500 FS11-500 FS09-500 FS09-550 FS88-500 FS13-500
FSCSOE Documentation:
Publication Title FSCSOE Basic Version FSCSOE Network Option FSCSOE Foxboro I/A Interface Option FSCSOE Yokogawa CS Interface Option Publication Number FS50-1xx* FS51-1xx* FS52-1xx* FS53-1xx*
* '1xx' is the release number. For example, the Basic Version manual for FSCSOE R130 is referenced as FS50-130.
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Table of Contents
Section 1 Introduction
1.1 Section overview
This section provides general information on the tools, documentation required, competence of people, and reference documents for maintenance, service and modification to Fail Safe Control (FSC) cabinets of Honeywell Safety Management Systems (HSMS). It covers the following topics:
See page
Section overview
Subsection 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Topic
Section overview............................................................................................... 1 Scope of this document .................................................................................... 1 Terminology ...................................................................................................... 2 Competence of people...................................................................................... 3 Precautions when working on FSC cabinets .................................................... 4 Hardware requirements .................................................................................... 6 Tools required................................................................................................... 7 Reference documents....................................................................................... 8
1.2
Scope
Scope of this document

This document is intended for engineers and other technical personnel who will perform any maintenance, service and modification to a Fail Safe Control (FSC) cabinet. Please note that this Service Manual is a generic document. This means that not all items mentioned in this document may necessarily apply to FSC cabinets in specific situations or applications. Every FSC cabinet is supplied with project-related documentation which provides detailed information and guidelines for the specific FSC cabinet(s).
Service Manual Section 1: Introduction
1.3
Terminology
The following terminology is important for proper understanding of this manual: An FSC system consists of a Central Part (CP) section and/or I/O section. The I/O modules are wired to the field termination assemblies (FTAs) and/or terminals using system interconnection cables (SICs). The FTAs and/or terminals may be located remotely (e.g. in a marshalling cabinet). An FSC cabinet consists of one or more cabinets. The following items can be mounted in an FSC cabinet: An FSC system with Central Parts, I/O racks, and FTAs and/or terminal (remote, if required), and A power supply system which may consist of AC/DC power supply units (PSUs), main switches, disconnectors and circuit breakers. It is possible that the required DC power is supplied directly. An FSC system is (re)started if the power to the FSC cabinet has not been disconnected. This will typically be the case during on-line modification (OLM) or after most maintenance tasks, e.g. exchanging Central Part modules. An FSC system is powered up after all power to the FSC cabinet has been disconnected. This will typically be the case during certain maintenance tasks that require the power to be cut off, e.g. replacing backplanes or supply input filters.
Terminology
FSC system
FSC cabinet
Start of an FSC system
Power-up of an FSC cabinet
Service Manual
Section 1: Introduction
1.4
Competence of people
Important! Any activities on the FSC cabinet may only be carried out by qualified, authorized and properly trained personnel. Failure to comply with the regulations and guidelines contained in this document may cause severe damage to the equipment and/or serious injury to people. Training Personnel that is to perform any kind of maintenance, service and/or modification to an FSC cabinet should have successfully completed the training required for the tasks to be performed. The following standard training courses are available: Fail Safe Controller (FSC) Managers Overview (course number: 4501). Introduction to IEC 61508 (course number: 4504). Fail Safe Controller (FSC) Implementation (course number: 4508). Fail Safe Controller (FSC) Maintenance (course number: 4505). Fail Safe Controller (FSC) On-Line Modification (course number: 4502). Fail Safe Controller (FSC) Advanced (course number: 4512). Fail Safe Controller (FSC) Total Package. For detailed information on the FSC-related training courses refer to Section 10 of this Service Manual. In addition to the above standard training courses, customized training can also be offered. These are specifically geared to the customer's specific needs. They will always be set up in cooperation with the customer, for example to focus on any discipline required for a particular site. Obtaining information on training For detailed information on the above-mentioned training courses please contact your local Honeywell affiliate or Honeywell SMS Regional Delivery Center (RDC).
1.5
Precautions when working on FSC cabinets

A number of considerations are important for working on FSC cabinets: Keeping the cabinet doors closed, and Electrostatic discharge (ESD). Each of these is discussed in more detail below.
Important considerations
Keep the doors closed
When not working on the FSC cabinet, make sure that you keep the doors closed in order to prevent dust and other particles from entering the FSC cabinet. Also, the electromagnetic immunity of the FSC system is reduced if the cabinet doors are open. Devices such as radio transmitters should preferably not be used close to an opened FSC cabinet. Make sure that you always close the cabinet doors after any operation specified in this Service Manual. It is important that you wear a properly connected electrostatic discharge (ESD) wrist-strap while removing, handling and installing any electronic components (see Figure 1-1).
Electrostatic discharge (ESD)
Figure 1-1 ESD wrist-strap connected to ESD bonding point
Service Manual
Slip the strap on your wrist like a wristwatch and connect its clip to the ESD bonding point, which is located inside the cabinet. There is no danger of receiving a shock from an approved wrist-strap. Be sure to keep any electronic component in a static-safe carrying pouch whenever it is not in use. An ESD kit is available through your local Honeywell service organization.
1.6
Hardware requirements
The following hardware requirements apply for working on FSC systems: An FSC user station is required for communication with the FSC system. For details refer to Section 2 of the FSC Software Manual ("Installation Guide"). No EPROM programmer and EPROM interface are required if the FSC system contains Central Part modules that support downloading to flash memory. If RS-485 serial communication is used between the FSC system and the FSC user station, an HSMS 07177/1/1 serial interface or other approved RS-485 interface is required. For testing spare parts, an FSC simulation unit or FSC training unit is required. For details refer to Appendix H of the FSC Software Manual ("Simulation Mode").
Hardware requirements
Service Manual
1.7
Tools
Tools required
Various tools are required during maintenance, service and modification to the FSC cabinet. As a minimum, the following tools are required: FSC user station (including all required software), 07170/1/1 EPROM programmer (depending on FSC system configuration), EPROM eraser (depending on FSC system configuration), EPROM remover (depending on FSC system configuration), Spare EPROMs (depending on FSC system configuration), 3-digit multimeter (voltage, current, and resistance), Pliers/spanners, Set of screwdrivers (both flatblade and Phillips), Torque wrench for connecting trunk/drop cables (depending on FSC system configuration), Several pairs of tongs, and Set of spanners (10 mm, 12 mm, 13 mm, 14 mm, etc.).
1.8
Reference documents
The documentation required for the maintenance, service and modification to an FSC cabinet can be split into two parts: Project-related documentation, and FSC user documentation. Both are discussed in more detail below:
Documentation
Project-related documentation
FSC cabinets are supplied with project-related documentation which provides detailed information and guidelines for the specific FSC cabinet(s). The following information may be included for a cabinet: General drawings, Power consumption calculation / heat dissipation calculation, Rack layout, Termination details, Power distribution, Communication overview, Functional Logic Diagrams (FLDs), Engineering documents, Factory Acceptance Test (FAT) document, and Site Acceptance Test (SAT) document (optional). The above-mentioned documentation will always relate to one or more specific FSC cabinets. Note: Always make sure that the latest versions of the project-related documentation is available. This is not necessarily the "as-built" documentation. If you work with old and/or obsolete documentation, this may lead to problems and/or delays during maintenance, service and modification.
Service Manual
FSC user documentation
There is also generic user documentation that applies to all FSC systems. This documentation provides technical details of the FSC hardware modules as well as user manuals for the FSC user software. The following manuals are available: FSC Hardware Manual. This is the technical catalog containing descriptions and technical specifications of the FSC hardware modules and components. FSC Software Manual. This is the user manual to the FSC Navigator software, which is used to interface with the FSC system. FSC Safety Manual. This is a document which provides general information on safety and safety-related systems, as well as implementation guidelines for FSC systems. FSC-SM documentation set. This is a set of manuals that provide information and guidelines for the implementation of the FSC Safety Manager (FSC-SM). Notes: 1. All references in this Service Manual made to the FSC Hardware Manual refer to the latest version of this document. 2. All references in this Service Manual made to the FSC Software Manual refer to Release 510 and higher. 3. All references in this Service Manual made to the FSC Safety Manual refer to Release 510 and higher. 4. All references in this Service Manual made to the FSC-SM documentation refer to the latest version of this documentation.
Left blank intentionally.
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Section 2 Installation Guide

This section provides general information on environmental conditions, transportation, unpacking, and installation of the FSC cabinet. It covers the following topics:
See page
Section overview
Subsection 2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5
Topic
Section overview............................................................................................. 11 Environmental conditions................................................................................ 12 Transportation conditions ............................................................................... 13 Storage conditions .......................................................................................... 14 Operating conditions....................................................................................... 15 FSC general cabinet layout ............................................................................ 16 Unpacking, moving and placement ................................................................ 19 Unpacking the equipment ............................................................................... 19 Moving preparations ....................................................................................... 23 Moving an FSC cabinet .................................................................................. 26 Interconnecting FSC cabinets ........................................................................ 33 After placement............................................................................................... 34
Honeywell SMS representative
It is recommended that a Honeywell SMS representative is present during the installation of the FSC cabinet. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the installation, they can be solved on the spot.
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2.2
Environmental conditions
The environmental conditions for FSC cabinets can be split into three areas: Transportation conditions, Storage conditions, and Operational conditions. Each of these areas is discussed in more detail in subsections 2.2.1 to 2.2.3.
Environmental conditions
Factory packing
In order to minimize the exposure to humidity, keep the factory packing intact during storage and transit. If it is necessary to unseal the equipment (e.g. for customs clearance), add more desiccant and reseal the packing. For transportation of the FSC cabinet over short distances (e.g. for transportation between the truck and storage location), a mobile lifter or fork lift can be used. Important! Take all necessary action to ensure that the FSC cabinet is properly secured during transportation to prevent damage to the equipment and/or serious injury to persons.
Mobile lifter / fork lift
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Section 2: Installation Guide
2.2.1
Transportation conditions
Transportation conditions
The transportation conditions for FSC cabinets are as follows: FSC cabinets are only to be transported using trucks that are equipped with the following: air suspension, a tail board, and a full enclosure. Temperature: Relative humidity: Vibration (sinusoidal): 25C to +80C (13F to +176F), max. 95% (non-condensing) excitation: sine-shaped with sliding freq. frequency range: 10-150 Hz loads: 10 Hz - 57 Hz: 0.075 mm 57 Hz - 150 Hz: 1 G no. of axes: 3 (x, y, z) traverse rate: 1 oct/min. 15 G in 3 axes (shock duration: 11 ms)
Shock:
FSC cabinets are only to be transported in their upright position unless specified otherwise by Honeywell SMS. During transportation, FSC cabinets should be secured to the truck to avoid damage to the equipment. Other items For transportation conditions of other items such as PCs, printers and mimic panels, refer to the information provided by the equipment manufacturer.
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2.2.2
Storage conditions
Storage conditions
The storage conditions for FSC cabinets are as follows: FSC cabinets are to be stored in their original packing. Temperature: Relative humidity: Vibration (sinusoidal): 25C to +80C (13F to +176F), max. 95% (non-condensing) excitation: sine-shaped with sliding freq. frequency range: 10-150 Hz loads: 10 Hz - 57 Hz: 0.075 mm 57 Hz - 150 Hz: 1 G no. of axes: 3 (x, y, z) traverse rate: 1 oct/min. 15 G in 3 axes (shock duration: 11 ms)
Shock:
FSC cabinets are only to be stored in their upright position unless specified otherwise by Honeywell SMS. Other items For storage conditions of other items such as PCs, printers and mimic panels, refer to the information provided by the equipment manufacturer.
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2.2.3
Operating conditions
Operating conditions
The operating conditions for FSC cabinets are as follows: Operating temperature: 0C to 60C (32F to 140F), measured at the Central Part rack(s) by the Diagnostic and Battery Module (DBM). Relative humidity: Vibration (sinusoidal): max. 95% (non-condensing) excitation: sine-shaped with sliding freq. frequency range: 10-150 Hz loads: 10 Hz - 57 Hz: 0.075 mm 57 Hz - 150 Hz: 1 G no. of axes: 3 (x, y, z) traverse rate: 1 oct/min. 15 G in 3 axes (shock duration: 11 ms)
Shock: Other items
For operating conditions of other items such as PCs, printers and mimic panels, refer to the information provided by the equipment manufacturer.
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2.3
FSC general cabinet layout

This subsection discusses the general layout of FSC cabinets. Please note that FSC cabinets are always made according to customer requirements, which means that deviations from the general description below are possible. Either of two standard Rittal cabinet types is used for FSC cabinets: PS 4806: Measurements: 80 x 60 x 200 cm (width x depth x height) (31 x 23 x 78 in). PS 4808: Measurements: 80 x 80 x 200 cm (width x depth x height) (31 x 31 x 78 in).
General
Cabinet types
Cabinet plinth
The FSC cabinet can be supplied with or without a plinth, depending on the customer requirements. Appendix A of this Service Manual specifies the dimensions and locations of the bolt-down holes for cabinets supplied with and without a plinth. A maximum of four PS 4806 or four PS 4808 Rittal cabinets can be built together and transported as one shipping section. This depends on the equipment mounted in the Rittal cabinets and the customer requirements. The height of the above-mentioned Rittal PS 4806 and PS 4808 cabinets does not include the plinth (normally 10 cm / 4 in) and the lifting eye bolts (5 cm / 2 in). The lifting eye bolts can be removed, if necessary. The weight of the FSC cabinet depends on the hardware installed and can go as high as 550 kg (1210 lb) per Rittal PS 4806 or PS 4808 cabinet.
Maximum number of cabinets
Height of cabinet
Weight of cabinet
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IP rating
By default, FSC cabinets have an Ingress Protection (IP) rating of IP20 in accordance with DIN VDE 0470. If required, this IP rating can be increased using additional measures. This is only done when specifically indicated in the customer requirements. For easy access to the equipment mounted in the FSC cabinet, one or more doors are mounted. Depending on the customer requirements, they may be mounted at the front and/or the rear of the FSC cabinet, and they may be full doors or double doors. For easy access to the rear of the circuit breaker rack(s), Central Parts rack(s) and I/O rack(s), the equipment is mounted in a swing frame. Opening the swing fame will also enable access to any equipment which is mounted behind the swing frame. Important! For safety reasons, do not open more than one swing frame at a time, even when the FSC cabinets are properly bolted to the floor.
Front / rear access
Swing frame
Bolting down cabinets
All FSC cabinets, once arrived at their final location, should be bolted down to the floor for safety reasons. Important! Opening swing frames when FSC cabinets are not properly bolted to the floor might tip over the FSC cabinets resulting in severe damage to the equipment and/or serious injury to persons.
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Cable entry
FSC cabinets are designed according to customer requirements. The following cables may enter the FSC cabinet (depending on the specifications): Earth/ground cables, Power/feeder cables, Communication cables, and Field cables. Depending on the customer requirements, these cables may enter the FSC cabinet from the top and/or bottom. For bottom entry, sliding floor plates are provided which can be adjusted to provide entry slots. For top entry, one adjustable sliding plate is provided. For top and/or bottom entry, the cables should be clamped firmly to the cable support/clamp rail. The clamping devices should be able to withstand a 45 kg (100 lb) pull. This prevents damage inside the FSC cabinet when pulling on cables outside the FSC cabinet. As a standard, the FSC cabinet includes a cable support/clamp rail at the bottom and/or at the top. If a plinth is factory-mounted, the cable support/clamp rail will be mounted in the plinth. Depending on customer requirements, it is possible that no cable support/clamp rail is mounted. This will, for example, be the case if a cable support/clamp rail is mounted below a false floor.
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2.4
Unpacking, moving and placement
2.4.1
Unpacking the equipment
Conditioned room
The unpacking of FSC cabinet should only be carried out in a conditioned room as the equipment is delicate and the humidity may affect the equipment, resulting in corrosion. For details on the environmental condition refer to subsection 2.2 of this Service Manual. Although the FSC cabinet is packed and transported with care, it is possible that paint is damaged. If any paint damage is detected, touch up these spots before transporting the FSC cabinet to its final location. This is the only way to prevent corrosion of the FSC cabinet. The standard colors used are: RAL 7032 (kieselgrau / pebble gray). Used for the cabinet enclosure. RAL 7022 (umbaugrau / dark gray). Used for the plinth. Depending on customer requirements, it is possible that different colors are used.
Paint damage
Ways of packing
FSC cabinets can be packed in either of three different ways: Wooden crating (FSC cabinet with or without plinth), Cardboard wrapping and FSC cabinet placed on a Europallet (FSC cabinet with or without plinth), or Cardboard wrapping and FSC cabinet placed on wooden beams (only FSC cabinets with plinth). Each of these packing methods is discussed in more detail below.
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Wooden crating
To unpack an FSC cabinet which is shipped in a wooden crate, take the following steps: 1. Look for visual damage of the wooden crating. If the wooden crate is damaged, be aware that the FSC cabinet inside the wooden crate may also be damaged. 2. Remove the top and sides of the wooden crate and look for visual damage on the FSC cabinet. If the FSC cabinet is damaged, inform the insurance company and Honeywell SMS. In any case, do not operate the equipment until conformation from Honeywell SMS has been obtained. Make sure to take pictures of the damage for insurance purposes. 3. If no damage was found, the FSC cabinet can be removed from the wooden pallet and transported to its final location (see subsections 2.4.2 and 2.4.3 for details). Notes: If the FSC cabinet is placed at a temporary location (e.g. to perform an integration test), make sure that the FSC cabinet is properly secured to the pallet, Europallet or wooden beams for safety reasons. Opening swing frames when FSC cabinets are not properly bolted to the floor might tip over the FSC cabinets resulting in severe damage to the equipment and/or serious injury to people. For safety reasons, do not open more than one swing frame at a time.
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Cardboard wrapping on Europallet
To unpack an FSC cabinet which is shipped in a cardboard wrapping placed on a Europallet, take the following steps: 1. Look for visual damage of the cardboard wrapping. If the cardboard wrapping is damaged, be aware that the FSC cabinet inside the wooden crate may also be damaged. 2. Remove the cardboard wrapping and look for visual damage on the FSC cabinet. If the FSC cabinet is damaged, inform the insurance company and Honeywell SMS. In any case, do not operate the equipment until conformation from Honeywell SMS has been obtained. Make sure to take pictures of the damage for insurance purposes. 3. If no damage was found, the FSC cabinet can be removed from the Europallet and transported to its final location (see subsections 2.4.2 and 2.4.3 for details). Notes: If the FSC cabinet is placed at a temporary location (e.g. to perform an integration test), make sure that the FSC cabinet is properly secured to the pallet, Europallet or wooden beams for safety reasons. Opening swing frames when FSC cabinets are not properly bolted to the floor might tip over the FSC cabinets resulting in severe damage to the equipment and/or serious injury to people. For safety reasons, do not open more than one swing frame at a time.
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Cardboard wrapping on wooden beams
To unpack an FSC cabinet which is shipped in a cardboard wrapping placed on wooden beams, take the following steps: 1. Look for visual damage of the cardboard wrapping. If the cardboard wrapping is damaged, be aware that the FSC cabinet inside the wooden crate may also be damaged. 2. Remove the cardboard wrapping and look for visual damage on the FSC cabinet. If the FSC cabinet is damaged, inform the insurance company and Honeywell SMS. In any case, do not operate the equipment until conformation from Honeywell SMS has been obtained. Make sure to take pictures of the damage for insurance purposes. 3. If no damage was found, the FSC cabinet can be removed from the wooden beams and transported to its final location (see subsections 2.4.2 and 2.4.3 for details). The wooden beams are connected to the plinth using M12x80 bolts. Use a wrench size 19 to disconnect the wooden beams. If three or four Rittal cabinets are built together as one shipping section, the wooden beam in the middle is not mounted to the plinth. This beam is only for additional support/clamp during transportation and/or storage. Notes: If the FSC cabinet is placed at a temporary location (e.g. to perform an integration test), make sure that the FSC cabinet is properly secured to the pallet, Europallet or wooden beams for safety reasons. Opening swing frames when FSC cabinets are not properly bolted to the floor might tip over the FSC cabinets resulting in severe damage to the equipment and/or serious injury to people. For safety reasons, do not open more than one swing frame at a time.
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2.4.2
Moving preparations
Background
Several basic points need to be kept in mind when planning the movement of an FSC cabinet. They include the following: Measurements of an FSC cabinet: PS 4806: Measurements: 80 x 60 x 200 cm (width x depth x height) (31 x 23 x 78 in). PS 4808: Measurements: 80 x 80 x 200 cm (width x depth x height) (31 x 31 x 78 in). If a plinth has been mounted, this adds about 10 cm (4 in) to the height. By default, the plinth is factory-mounted. Lifting eye bolts (which are removable) add about 5 cm (2 in) to the height. The weight of the FSC cabinet depends on the hardware installed and can go as high as 550 kg (1210 lb) per Rittal PS 4806 or PS 4808 cabinet.
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Checklist
Table 2-1 provides a checklist to be used when planning the movement of an FSC cabinet. Table 2-1 Move preparation checklist
Item 1
Action Travel Route
Notes Chart the equipment's route of travel regarding: loading doors height and location, elevators size, capacity, and availability, aisles number, size, and layout, doorways number and size, hallways size, restrictions, and bends, stairs and ramps may require some type of lifting, and rigging of equipment if needed.
Check
2 3 4
Space Floor loading Power distribution
Is there enough space to hold the equipment? Will the floor in all areas be strong enough? Check for proper transformer sizes, distribution panels and sufficient outlets for support, test and maintenance equipment. Be sure that proper grounds are available. Make sure that conduits and cable trays are large enough and of the proper type to accommodate all of the required cables. Are lighting and other environmental requirements adequate? Provide security clearances for the installation crew if it is not composed of regular employees. Are all responsibilities clearly defined and understood? Are telephones and telephones numbers available for: Operator Emergency, and Your local Honeywell SMS affiliate
5 6
Grounding Conduits and cable trays Environment Security Responsibilities Communications
7 8 9 10
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Preparations
Table 2-2 provides a checklist to be used when preparing the electronics room for an FSC cabinet. Table 2-2 Preparing the electronics room
Item 1
Action Static electricity
Notes Reduce the ESD-borne failures by: stripping the floors of any wax to prevent static charge buildup, using anti-static spray on floors, furniture and fabric in the work area, and placing a sign on or near the equipment that states circuit boards are not to be handled without wearing a ground strap.
Check
2 3 4 5
Tack rugs Fire prevention Room layout Cabinet bolt-down
Placed at all entrances, tack rugs catch dust, grit and abrasives from other areas. Consult with the local fire prevention authority to select fire extinguishers suitable for electrical fires. Prepare an electronics room layout diagram for cabinet placement. Bolt down the FSC cabinet to the floor. (Refer to Appendix A for placement and dimensions of the bolt-down holes.)
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2.4.3
Moving an FSC cabinet
Moving
FSC cabinets can be moved in any one of four methods: Fork lift, Mobile lifter, Roller, or Crane. Each of these methods is described in more detail below. Note: When moving FSC cabinets: Use lifters with sufficient capacity. The weight of the FSC cabinet depends on the hardware installed and can go as high as 550 kg (1210 lb) per Rittal PS 4806 or PS 4808 cabinet. Do not tilt the FSC cabinet more than 15 front or back to avoid damage to the doors and/or equipment inside the FSC cabinet.
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Fork lift
The FSC cabinet is moved by fork lift to its final location. Table 2-3 below lists special considerations regarding the use of a fork list to move the equipment. Table 2-3 Fork lift considerations
Number 1 Consideration Move the equipment to the electronics room by fork lift; remove the fork lift by placing the equipment onto the lumber pieces by 10 cm (4 in) as illustrated in Figure 2-1. Tip the cabinet off the lumber and onto the floor; remove the lumber. Manually move the cabinet to the exact final position.
2 3
Solid piece or combination of lumber pieces to match skid or pallet height (nail together). Move cabinet onto the lumber.
Figure 2-1 Placement of an FSC cabinet onto lumber
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Mobile lifter
As illustrated in Figure 2-2, the FSC equipment is placed on a transport skid made from angle iron. It is then moved with a mobile lifter. Table 2-4 lists special considerations regarding the use of a mobile lifter to move the equipment. Table 2-4 Mobile lift considerations
Number 1 2 3 4 5 6 Consideration Tilt the equipment slightly and slide one of the angle irons used to make up a transport skid underneath the cabinet as in Figure 2-2. Repeat the above step for the other angle. Insert a strip of heavy cardboard between each angle iron and the equipment finish. Tighten the angle irons against the cabinet by tapping slightly. Insert and tighten two 12 mm (0.5 in) minimum, threaded cross rods as in Figure 2-2 and Figure 2-3. Spread the lifter forks to 80 cm (31 in) centers and put them under each cross rod. Place the fork's dowels between the cross rods and the cabinet, just touching the cross rods. Place wooden spacer blocks along the forks, long enough to press the cross rods against the fork dowels. Position a protective plate using braces as shown in Figure 2-2. Be sure that the plate does not press against handles or other cabinet hardware. Raise both lifter forks evenly until the equipment clears the shipping skid; pull it out of the way. Wheel the equipment to the final position in the electronics room; lower it to the floor. Pull out the mobile lifters. Dismantle and remove the angle iron transport skid. Manually place the cabinet in the exact final position.
7 8 9 10 11 12
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Mobile lifters
(continued)
Figure 2-2 shows how the FSC cabinet is to be placed using a mobile lifter.
Wooden brace and protective plate
Hydraulic jack
Fork dowel Cross rod 2" x 4" Spacer block Mobile lifter (2 req'd) Angle iron transport skid Equip ment
Figure 2-2 Placement using a mobile lifter
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Mobile lifters
(continued)
Figure 2-3 shows how the FSC cabinet is to be placed using a mobile lifter or crane.
Spreader
Angle iron support
1.25 cm (0.5 in) (minimum) threaded cross rods with nuts
Figure 2-3 Lifting equipment by mobile lifter or crane
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Roller method
As illustrated in Figure 2-4, using the roller method the FSC cabinet is moved to its final location by placing pipe rollers under a transport skid made of angle iron. Table 2-5 lists special considerations regarding the use of the roller method to move the equipment. Table 2-5 Roller method considerations
Number 1 2 3 Consideration Use one of the previous methods to move the cabinet to a location where rollers are to be used. Install the angle iron transport skid as in the mobile lifter method. Place 12 mm (1/2 inch) pipes under the transport skid as shown in Figure 2-4. ATTENTION 4 The load must be on the angle irons, not the cabinet.
Roll the cabinet to its final location. ATTENTION all times. At least three pipes must be under the transport skid at
5 6
When the cabinet is near the final location, tilt it and pull out the pipes, the middle one last. Dismantle the transport skid and position the cabinet manually to the exact final location.
Angle iron supports 2.5 cm (1 in) pipes (minimum)
Figure 2-4 Moving the FSC cabinet using the roller method
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Crane method
In this method the FSC cabinet is lifted into place with a crane. Use either an angle iron transport skid (see Figure 2-4) or the lifting eyebolts installed on each section of Rittal cabinets (see Figure 2-5).
One bay
x x x
x x x x x x x x x x x
Two bays x Three bays
Four bays
Figure 2-5 Eyebolt crane method Leveling an bolt-down The FSC cabinet does not include levelers. It may be necessary to hand-fit shims underneath the FSC cabinet in order to make the cabinet sit solidly. All FSC cabinets, when arrived at their final location, should be bolted to the floor for safety reasons. Opening swing frames when the FSC cabinets are not properly bolted to the floor might tip over the FSC cabinets resulting in severe damage to the equipment and/or serious injury to people. Appendix A of this Service Manual shows the dimensions and locations of the bolt-down holes.
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2.4.4
Interconnecting FSC cabinets
Interconnecting FSC cabinets
It is possible that FSC cabinets are shipped in sections, which have to be bolted together on site. The general drawings of the project-related documentation will always show how the FSC cabinets should be placed. The side plates should always be mounted during transportation and shipment of the FSC cabinet as these provide extra mechanical strength. To interconnect FSC cabinets, take the following steps: 1. Unpack one section as described in this manual (see subsection 2.4.1). 2. Remove the appropriate side plate of the FSC cabinet (see the general drawings of the project-related documentation). 3. Place the FSC cabinet at its final location and bolt the FSC cabinet to the floor (see subsection 2.4.3). 4. Unpack the next section as described in this manual (see subsection 2.4.1). 5. Remove the appropriate side plate of the FSC cabinet (see the general drawings of the project-related documentation). 6. Place the FSC cabinet at its final location and bolt the FSC cabinet to the floor (see subsection 2.4.3). 7. Use the mounting kit supplied (consisting of interconnection plates and interconnection brackets) to connect the FSC cabinets together. For removing the red swing frame brackets refer to subsection 2.5. 8. Connect an earth strap, which can be removed from one of the obsolete side plates, between the connected FSC cabinets. Repeat the above steps for all FSC cabinets involved. The side plates removed from the FSC cabinets are no longer needed.
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2.5
After placement
This subsection lists items that should be checked before proceeding with the start-up of the FSC cabinet as described in Section 4 of this Service Manual. They are related to the following: Swing frame brackets, Swing frame adjustment, and Forced ventilation. Each of these items is discussed in more detail below.
After placement
Swing frame brackets
Red transportation brackets are mounted on each swing frame of the FSC cabinet in order to ensure that the swing frame is not damaged during transportation. Two brackets are mounted for each swing frame. These should be removed after the FSC cabinet has been placed at its final location. Note: If the FSC cabinet is placed at a temporary location (e.g. to perform an integration test), make sure the red transportation brackets are mounted again before shipment of the FSC cabinet to its final location in order to avoid damage during transportation.
Adjusting the swing frame
After the FSC cabinet has been placed at its final location, check that the swing frame opens smoothly. If it does not, you should adjust the mounting kit which secures the swing frame. Important! Take precautions to prevent that the swing frame will be dismounted from the mounting kit during adjustment of the swing frame. If you do not, a very dangerous situation may arise which may cause damage to the equipment and/or serious injury to persons as the swing frame may be dislocated from the mounting kit during adjustment.
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Forced ventilation
In most FSC cabinets, fans are mounted in the roof and cabinet doors to provide forced ventilation inside the FSC cabinet. Take the following precautions to ensure this forced ventilation: Do not obstruct the fans. This might result in malfunction of the fans and/or other dangerous situations. Do not obstruct the filters. If false air enters the FSC cabinet, more dust particles will enter the FSC cabinet and this may result in a malfunction of the equipment. By default, FSC cabinets have an Ingress Protection (IP) rating of IP20 in accordance with DIN VDE 0470. If required, this IP rating can be increased using additional measures. This is only done when specifically indicated in the customer requirements.
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Section 3 Connection of External Cables

This section provides information on connection of external cables to the FSC cabinet. It covers the following topics:
See page
Section overview
Subsection 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.7 3.7.1 3.7.2 3.7.3 3.7.4
Topic
Section overview............................................................................................. 37 Interconnection wiring..................................................................................... 38 Separation and routing of cables and wiring .................................................. 39 Earth/grounding cables................................................................................... 40 Introduction ..................................................................................................... 40 Safety earth/ground ........................................................................................ 41 Instrument earth/ground ................................................................................. 41 Ex(i) earth/ground ........................................................................................... 41 Power/feeder cables ....................................................................................... 42 Introduction ..................................................................................................... 42 Supply voltages .............................................................................................. 42 AC/DC power supply units.............................................................................. 43 Connecting AC power/feeder cables .............................................................. 43 DC power ........................................................................................................ 45 Connecting DC power/feeder cables.............................................................. 45 Field cables..................................................................................................... 48 Introduction ..................................................................................................... 48 I/O module wiring using FTA-T devices.......................................................... 49 I/O module wiring using FTA-E....................................................................... 52 I/O module wiring using terminals .................................................................. 55 I/O module wiring using third-party devices.................................................... 58 Communication cables ................................................................................... 61 Introduction ..................................................................................................... 61 Connecting fiber optic cables.......................................................................... 62 Connecting trunk cables to taps ..................................................................... 66 Connecting other communication cables........................................................ 66
Installation completed
At this point, the installation of the FSC cabinet as described in Section 2 of this Service Manual should have been completed successfully. It is recommended that a Honeywell SMS representative is present during work on the FSC cabinet. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the installation, they can be solved on the spot.
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Service Manual Section 3: Connection of External Cables
3.2
Interconnection wiring
If an FSC cabinet consists of multiple Rittal cabinets, it is possible that they will be shipped as separate shipping sections. This can be due to the total size of the Rittal cabinets, total weight, or customer requirements. If FSC cabinets are shipped as separate sections, interconnection wiring between the different shipping sections may need to be installed. This wiring may be any of the following: Earth/grounding cables, Power distribution cables, System interconnection cables (SICs), and Communication cables. The project-related documentation should provide a list of all wires/cables to be connected between the different sections. Refer to this list for details on the interconnection wiring.
Interconnection wiring
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Section 3: Connection of External Cables
3.3
Separation and routing of cables and wiring
Separation and routing of cables and wiring
The wires/cables carrying different voltage levels must be separated according to the principles as shown in Table 3-1 below. Table 3-1 Routing of cables carrying different voltages
Voltage level in cable 5 Vdc 24 Vdc 48 Vdc 60 Vdc 110 Vdc 220 Vdc Requirements Cables carrying this voltage must always be routed separately from other voltages. Cables carrying these voltages may be routed together.
Cables carrying these voltages may be routed together.
Notes: 1. AC voltages must be routed separately from DC voltages. 2. Wires/cables carrying communication signals must be routed separately from the voltage-carrying wires/cables. 3. Communication cables may cross voltage-carrying wires but they may not be routed together. (Communication cables running from FSC communication modules to FSC communication boards and/or devices are typically RS-485, RS-232 and RS-422.) 4. If 5 Vdc and V-bus flatcables need to be routed to an adjacent FSC system cabinet, these cables/wires must be separated from other cables/wires which need to be routed to these cabinets. 5. Fiber-optic cables may be routed with other cables, but they should be routed in such a way that they are not exposed to physical stress.
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3.4
Earth/grounding cables
3.4.1
Introduction
Cable types
The cables that enter the FSC cabinet can be divided into four different groups: Earth/grounding cables (see this subsection), Power/feeder cables (see subsection 3.5), Field cables (see subsection 3.6), and Communication cables (see subsection 3.7). Details on the requirements with regard to separation and routing of cables and wiring are provided in subsection 3.3.
Earth bars
Three different earth bars may be present in FSC cabinet: Safety earth/ground, Instrument earth/ground (also called master reference ground, or MRG), and Ex(i) earth/ground. As a standard, the FSC cabinet is a floating system, which means that the 0 Vdc of the voltages used in the FSC cabinet are not connected to an earth/ground bar and/or earth/ground point. The cables from the safety earth/ground bar and instrument earth/ground bar can be connected together to the safety earth rod of the plant.
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3.4.2
Safety earth/ground
Each FSC cabinet is equipped with a safety earth/ground bar, which is connected to the FSC cabinet structure using an earth strap. The following items are connected to the safety earth/ground bar: All mechanical parts of the FSC cabinet, The armor wire of the field cables, and The cable from the plant safety earth/ground. The cable from the plant safety earth/ground can also be connected to the safety earth/ground bolt, which is available in the FSC cabinet. Note: The safety earth/ground and instrument earth/ground can be connected together at one and one point only.
Safety earth/ground
3.4.3
Instrument earth/ground
Each FSC cabinet is equipped with an instrument earth/ground bar. The following items are connected to this earth/ground bar: Shields of field cables, Instrument earth/ground wires of the communication boards, and The cable from the plant instrument earth/ground. Note: The safety earth/ground and instrument earth/ground can be connected together at one and one point only.
3.4.4
Ex(i) earth/ground
The Ex(i) earth/ground bar is used for the earth connection of Ex(i) equipment. This can, for example, be the MTL or Pepperl+Fuchs equipment as mentioned in subsection 3.6 of this Service Manual. A separate earth rod will be installed for the Ex(i) earth/ground.
Ex(i) earth/ground
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3.5
Power/feeder cables
3.5.1
Introduction
The cables that enter the FSC cabinet can be divided into four different groups: Earth/grounding cables (see subsection 3.4), Power/feeder cables (see this subsection), Field cables (see subsection 3.6), and Communication cables (see subsection 3.7). Details on the requirements with regard to separation and routing of cables and wiring are provided in subsection 3.3.
Cable types
3.5.2
Supply voltages
The power/feeder cables supply the FSC cabinet with the various voltages required to ensure correct operation of the FSC cabinet. AC and/or DC voltages may be supplied to the FSC cabinet. The voltages required depend on the configuration of the FSC system and the customer requirements. However, 24 Vdc is always required by the FSC system hardware. The 24 Vdc is normally generated by power supply units (PSUs) mounted in the FSC cabinet. The power/feeder cables for AC voltages will be connected to fuse terminals or a main circuit breaker (see subsection 3.5.4). The power/feeder cables for DC voltages will be connected to fuse terminals, a main circuit breaker or a power distribution rail (see subsection 3.5.6).
Voltage types
High voltages
Equipment with high voltages (i.e. above 40 Vdc or 30 Vac) are covered by a protective plate or cover. If these voltages are connected, take extra precautions when the protective plates/covers are removed. After connecting the power/feeder cables, make sure that you put the protective plates/covers back into place.
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3.5.3
AC/DC power supply units
AC/DC power supply units
Only TV-approved power supply units (PSUs) may be used in conjunction with the FSC system. The following power supply units are currently TV approved: Delta 1200 S 24 P067 (24 Vdc power supply, 45 A), Delta M24-20HE (24 Vdc power supply, 20 A), Delta M24-12HE (24 Vdc power supply, 12 A), Delta M48-10HE (48 Vdc power supply, 10 A), and Delta M60-5HE (60 Vdc power supply, 5 A). For detailed information on the power and frequency requirements refer to the FSC Hardware Manual. Note: If the incoming AC power/feeder cables do not meet the requirements as mentioned in the data sheets of the power supply units (PSUs), the FSC system should not be operated.
3.5.4
Connecting AC power/feeder cables
Connecting AC power/feeder cables
The procedure below describes the steps to be taken to connect the AC power/feeder cables to the FSC cabinet. The AC power/feeder cables can be connected to: A main circuit breaker, or Fuse terminals. Before connecting the AC power/feeder cables, check the following items in the FSC cabinet: All main circuit breakers should be off. All primary switches should be off. All secondary disconnectors should be off. All circuit breakers should be off. All fuses should be removed from the fuse terminals. All fuses should be removed from the FTAs. All knife-type terminals should be opened.
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Procedure
The next procedure should be repeated for each power/feeder cable: 1. Before connecting the AC power/feeder cable, check that the circuit breaker mounted in the AC distribution panel (which provides the AC power to the FSC cabinet) is switched off. 2. Remove the protective plate/cover from the main circuit breaker and/or fuse terminals inside the FSC cabinet. 3. Connect the AC power/feeder cable to the corresponding main circuit breaker and/or fuse terminals installed in the FSC cabinet. For detailed information on which cable should be connected refer to the power distribution drawings, which are part of the project-related documentation. For detailed information on the exact location of the main circuit breaker and/or fuse terminals refer to the general drawings, which are part of the project-related documentation. 4. Measure the resistance between earth of the FSC cabinet frame and the earth connection of the AC power/feeder cable. The resistance should be 0.1 Ohm. If the resistance is higher, the cause should be identified and solved before continuing the connection of AC power/feeder cables. 5. Place the required ferrites on each AC power/feeder cable (if not already installed in the FSC cabinet). For detailed information on ferrites refer Appendix F of this Service Manual. Notes: a) Make sure that the various AC power/feeder cables are connected to the correct main circuit breaker and/or fuse terminals as high voltages will damage the equipment of the FSC cabinet. b) If the incoming AC power/feeder does not meet the requirements as mentioned in the data sheets of the power supply units (PSUs), the FSC system should not be operated. c) Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring. 6. Switch on the main breakers in the AC distribution panel, and measure the incoming AC voltage on the main circuit breaker and/or fuse terminals installed in the FSC cabinet. 7. After measuring the AC voltage, switch off the circuit breaker in the AC distribution board. 8. Put the protective plate/cover from the main circuit breaker and/or fuse terminals in the FSC cabinet back into place.
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3.5.5
DC power
If DC voltages are supplied to the FSC cabinet, these should be within the following range to ensure correct operation of the FSC system: 110 Vdc: +25% / 15%. 60 Vdc: +15% / 15%. 48 Vdc: +15% / 15%. 24 Vdc: +30% / 15% (for FSC system). It is recommended that the incoming 24 Vdc voltage be adjusted to 25 Vdc (identical to the approved Delta power supply units supplied by HSMS). This is to ensure that the voltage at the modules will always be in accordance with requirements, taking into account the voltage drop in the FSC cabinet. Note: If the incoming DC power/feeders cables do not meet the requirements mentioned above, the FSC system should not be operated.
DC power
3.5.6
Connecting DC power/feeder cables

The procedure below discusses the steps to be taken to connect the DC power/feeder cables to the FSC cabinet. The DC power/feeder cables can be connected to: A main circuit breaker, Fuse terminals, or A power distribution rail. Before connecting the DC power/feeder cables, check the following items in the FSC cabinet: All main circuit breakers should be off. All primary switches should be off. All secondary disconnectors should be off. All circuit breakers should be off. All fuses should be removed from the fuse terminals. All fuses should be removed from the FTAs. All knife-type terminals should be opened.
Connecting DC power/feeder cables
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Procedure
The next procedure should be repeated for each power/feeder cable: 1. Before connecting the DC power/feeder cable, check that the circuit breaker mounted in the DC distribution panel (which provides the DC power to the FSC cabinet) is switched off. 2. Remove the protective plate/cover from the main circuit breaker and/or fuse terminals inside the FSC cabinet. 3. Connect the DC power/feeder cable to the corresponding main circuit breaker, fuse terminals and/or power distribution rails installed in the FSC cabinet. For detailed information on which cable should be connected refer to the power distribution drawings, which are part of the projectrelated documentation. For detailed information on the exact location of the main circuit breaker, fuse terminals and/or power distribution rails refer to the general drawings, which are part of the project-related documentation. 4. Measure the resistance between earth of the FSC cabinet frame and the earth connection of the DC power/feeder cable. The resistance should be 0.1 Ohm. If the resistance is higher, the cause should be identified and solved before continuing the connection of DC power/feeder cables. 5. Place the required ferrites on each DC power/feeder cable (if not already installed in the FSC cabinet). For detailed information on ferrites refer Appendix F of this Service Manual. Notes: a) Make sure that the various AC power/feeder cables are connected to the correct main circuit breaker and/or fuse terminals as high voltages will damage the equipment of the FSC cabinet. b) If the incoming AC power/feeder does not meet the requirements as mentioned in the data sheets of the power supply units (PSUs), the FSC system should not be operated. c) Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring. 6. Switch on the main breakers in the DC distribution panel, and measure the incoming DC voltage on the main circuit breaker, fuse terminals and/or power distribution rails installed in the FSC cabinet.
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7.
After measuring the DC voltage, switch off the circuit breaker in the DC distribution board. 8. Put the protective plate/cover from the main circuit breaker, fuse terminals and/or power distribution rails in the FSC cabinet back into place.
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3.6
Field cables
3.6.1
Introduction
Cable types
The cables that enter the FSC cabinet can be divided into four different groups: Earth/grounding cables (see subsection 3.4), Power/feeder cables (see subsection 3.5), Field cables (see this subsection), and Communication cables (see subsection 3.7). This section deals with the field cables. Field cables are used for interconnection between the FSC cabinets and other equipment, for example marshalling cabinets and/or local panels. Details on the requirements with regard to separation and routing of cables and wiring are provided in subsection 3.3.
I/O module wiring
Field wiring is not connected directly to the I/O modules themselves. Rather, as illustrated in Figure 3-1, Figure 3-3 and Figure 3-5, these connections are made via: Terminal-type FTAs (FTA-T), Elco-type FTAs (FTA-E), Terminals, or Third-party devices. Each of the connection methods is discussed in more detail in the following subsections.
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3.6.2
I/O module wiring using FTA-T devices
Using FTA-T
FTA-T modules are field termination assemblies that are fitted with screw terminals to connect field wires directly. They are electrically passive devices which simply pass incoming or outgoing signals between the field and I/O modules. Figure 3-1 below illustrates a typical routing layout of the internal wiring between I/O modules and FTA-T via system interconnection cables (SIC-Cs).
Backplane
FTA-T
FTA connector I/O module connector
I/O module System I/O cable
Terminal block
Figure 3-1 Typical routing of internal wiring between I/O modules and FTA-T via SIC-Cs Connecting FTA-T Fields cables are used for interconnection between FTA-Ts and other equipment, e.g. marshalling cabinets and/or local panels. The FTA-Ts need not necessarily be placed in the FSC cabinet. They can also be placed remotely (e.g. a marshalling cabinet). Before connecting the field cables, take the following steps to prevent damage to the FSC equipment: Open all knife-type terminals installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from terminals which are used for I/O wiring installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from the FTAs.
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To connect the field cables, take the following steps for each cable: 1. Secure the field cable to the cable support/clamp rail of the FSC cabinet. 2. Route the field cable to the FTA-Ts where the connections should be made. 3. Connect all cores to the corresponding terminals on the FTA-Ts according to the termination details. Leave sufficient slack on the cores to avoid tension on the connections on the FTA-Ts. 4. If required, connect the earth wire from the field cable to the FTA-T. 5. Use tire wraps to tighten the field cable in the cable duct. Note: Do not close any knife-type terminals or place the fuses back into the fuse terminals or FTA-Ts as long as no power is applied to all systems and not all signals have been checked for high voltages and short circuiting which may be caused by wiring faults in the field and/or junction boxes. These high voltages will damage the equipment of the FSC cabinet. The voltages and short circuiting need to be checked on the external devices. 6. Close all knife-type terminals and put the fuses back into the terminals used for the I/O wiring and the FTAs.
The next steps are only applicable to field cables carrying signals which are connected via FTA-Ts to the following type of FSC I/O modules: 10102/x/x (analog input module), 10214/x/x (loop-monitored digital output module), or 10216/x/x (loop-monitored digital output module). 7. Remove the field cable from the cable support/clamp rail. 8. Remove the insulation at the height of the cable support/clamp rail. 9. Secure the field cable with the blank shield to the cable support/clamp rail (see Figure 3-2 on the next page).
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Shielded cables (stripped)
Cable clamps
Cable clamp rails

Figure 3-2 Bonding of shielded cables (FTA-T) For detailed information on the exact location of the FTA-Ts refer to the general drawings, which are part of the project-related documentation. For detailed information on the FSC I/O modules connected to the FTA-Ts via SIC-Cs, refer to the termination details, which are part of the project-related documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
FTA-T maximum wire diameter FTA-T wire strip length FTA-T tightening torque
For detailed information on the maximum wire diameter refer to the data sheet of the applicable FTA-T module in the FSC Hardware Manual. For detailed information on the wire strip length refer to the data sheet of the applicable FTA-T module in the FSC Hardware Manual. For detailed information on the tightening torque refer to the data sheet of the applicable FTA-T module in the FSC Hardware Manual.
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3.6.3
I/O module wiring using FTA-E
Using FTA-E
FTA-E modules are field termination assemblies that are fitted with a standard Elco E-56 connector to connect E-56 system cables. They are electrically passive devices which simply pass incoming or outgoing signals between the field and I/O modules. Figure 3-3 below illustrates a typical routing layout of the internal wiring between I/O modules and FTA-E via system interconnection cables (SIC-Cs).
Backplane
FTA-E
FTA connector I/O module connector
I/O module System I/O cable
Elco 56/54-pin (E56) connector
Figure 3-3 Typical routing of internal wiring between I/O modules and FTA-E via SIC-Cs Connecting FTA-E System cables (Elco cables) are used for interconnection between FTA-Es and other equipment, e.g. a DCS system and/or marshalling cabinets. The FTA-Es need not necessarily be placed in the FSC cabinet. They can also be placed remotely (e.g. a marshalling cabinet). If system cables are used, the following is assumed: The system cable has not been connected to the external device. The system cable end at the external device is a system cable plug or has a termination with crimp pins which are suitable for connection to screw terminals.
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Before connecting the system cables, take the following steps to prevent damage to the FSC equipment: Open all knife-type terminals installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from terminals which are used for I/O wiring installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from the FTAs. To connect these system cables, take following steps for each cable: 1. Secure the system cable to the cable support/clamp rail of the FSC cabinet. 2. Route the system cable to the FTA-E where the connection should be made. Leave some slack in the system cable to allow connection of the system cable plug to the FTA-E. Do not connect the system cable plug to the FTA-E at this point. 3. Use tire wraps to tighten the system cable to the cable tray. 4. Roll the system cable to the external device (e.g. DCS system or marshalling cabinet). 5. Connect the system cable end to the external device (e.g. DCS system and/or marshalling cabinet). 6. Secure the system cable to the cable support/clamp rail of the external device (e.g. DCS system or marshalling cabinet). Note: Do not connect the system cable connector to the FTA-E, close any knife terminals, or place the fuses back in the fuse terminals or FTA-Es as long as no power is applied to all systems and not all signals have been checked for high voltages and short circuiting which may be caused by wiring faults in the field and/or junction boxes. These high voltages will damage the equipment of the FSC cabinet. The voltages and short circuiting need to be checked on the external devices. 7. Connect the system cable connector to the FTA-E mounted in the FSC cabinet, close all knife-type terminals, and place back the fuses in the terminals used for the I/O wiring and the FTAs.
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The next steps are only applicable to system cables carrying signals which are connected via FTA-Es to the following type of FSC I/O modules: 10102/x/x (analog input module), 10214/x/x (loop-monitored digital output module), or 10216/x/x (loop-monitored digital output module). 8. Remove the system cable from the cable support/clamp rail. 9. Remove the insulation at the height of the cable support/clamp rail. 10. Secure the system cable with the blank shield to the cable support/clamp rail (see Figure 3-4 below). Shielded cables (stripped)
Cable clamps
Cable clamp rails

Figure 3-4 Bonding of shielded cables (FTA-E) For detailed information on the exact location of the FTA-Es refer to the general drawings, which are part of the project-related documentation. For detailed information on the FSC I/O modules connected to the FTA-Es via SIC-Cs, refer to the termination details, which are part of the project-related documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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3.6.4
I/O module wiring using terminals
Using terminals
Figure 3-5 illustrates a typical routing layout of the internal wiring between I/O modules and terminals via system interconnection cables with crimp pins (SIC-Ps).
I/O module connector (a) Crimp pins
System interconnection cable
I/O module connector (b)
Figure 3-5 Typical layout of a SIC-P cable Connecting terminals Fields cables are used for interconnection between terminals placed in the FSC cabinet and other equipment, e.g. marshalling cabinets and/or local panels. The terminals need not necessarily be placed in the FSC cabinet. They can also be placed remotely (e.g. a marshalling cabinet). Before connecting the SIC-P and field cables, take the following steps to prevent damage to the FSC equipment: Open all knife-type terminals installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from terminals which are used for I/O wiring installed in the FSC cabinet and/or marshalling cabinet.
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When the terminals are placed remotely (e.g. marshalling cabinet), take the following steps for each SIC-P cable: 1. Route the SIC-P cables from the FSC cabinet to the marshalling cabinet. 2. Secure the SIC-P cable to the cable support/clamp rail of the FSC cabinet. 3. Secure the SIC-P cable to the cable support/clamp rail of the marshalling cabinet. 4. Route the SIC-P cable to the terminals where the connections should be made. 5. Connect all cores from the SIC-P cable to the corresponding terminals in accordance with the termination details, which are part of the project-related documentation. Leave sufficient slack on the cores to avoid tension on the connections on the terminals. 6. Use tire wraps to tighten the field cable in the cable duct. To connect the field cables, take following steps for each cable: 1. Secure the field cable to the cable support/clamp rail of the FSC cabinet. 2. Route the field cable to the terminals where the connections should be made. 3. Connect all cores to the corresponding terminals in accordance with the termination details. Leave sufficient slack on the cores to avoid tension on the connections on the terminals. 4. Use tire wraps to tighten the field cable in the cable duct. Note: Do not close any knife-type terminals or place the fuses back into the fuse terminals as long as no power is applied to all systems and not all signals have been checked for high voltages and short circuiting which may be caused by wiring faults in the field and/or junction boxes. These high voltages will damage the equipment of the FSC cabinet. The voltages and short circuiting need to be checked on the external devices. 5. Close all knife-type terminals and place back the fuses in the terminals used for the I/O wiring and the FTAs.
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The next steps are only applicable to field cables carrying signals which are connected via FTA-Ts to the following type of FSC I/O modules: 10102/x/x (analog input module), 10214/x/x (loop-monitored digital output module), or 10216/x/x (loop-monitored digital output module). 6. Remove the field cable from the cable support/clamp rail. 7. Remove the insulation at the height of the cable support/clamp rail. 8. Secure the field cable with the blank shield to the cable support/clamp rail (see Figure 3-6). Shielded cables (stripped)
Cable clamps
Cable clamp rails

Figure 3-6 Bonding of shielded cables (terminals) For detailed information on the exact location of the terminals refer to the general drawings, which are part of the project-related documentation. For detailed information on the FSC I/O modules connected to the terminals via SIC-Cs, refer to the termination details, which are part of the project-related documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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Terminal maximum wire diameter Terminal wire strip length Terminal tightening torque
For detailed information on the maximum wire diameter refer to the data sheets of the applicable terminals. For detailed information on the wire strip length refer to the data sheets of the applicable terminals. For detailed information on the tightening torque refer to the data sheets of the applicable terminals.
3.6.5
I/O module wiring using third-party devices
Using third-party devices
Two manufactures currently provide devices (backplanes) which can be connected to the FSC I/O modules using SIC-C cables: Pepperl + Fuchs and MTL. These backplanes are used for interconnection between the FSC I/O modules and: Ex(i) field devices. In this case all field cables should be colored blue and the field cables should be segregated from all other non-Ex(i) field cables. The cables should also be segregated in the FSC cabinet. Non-Ex(i) field devices. Standard-color field cable can be used. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
Connecting third-party devices
Fields cables are used for interconnection between the third-party devices placed in the FSC cabinet and other equipment, e.g. marshalling cabinets and/or local panels. The third-party devices need not necessarily be placed in the FSC cabinet. They can also be placed remotely (e.g. a marshalling cabinet).
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Before connecting the field cables, take the following steps to prevent damage to the FSC equipment: Open all knife-type terminals installed in the FSC cabinet and/or marshalling cabinet. Remove all fuses from terminals which are used for I/O wiring installed in the FSC cabinet and/or marshalling cabinet. To connect the field cables, take following steps for each cable: 1. Secure the field cable to the cable support/clamp rail of the FSC cabinet. 2. Route the field cable to the terminals of the third-party device where the connections should be made. 3. Connect all cores to the corresponding terminals on the third-party device in accordance with the termination details. Leave sufficient slack on the cores to avoid tension on the connections on the terminals on the third-party device. Special field connectors may be required, depending on the manufacturer. 4. Use tire wraps to tighten the field cable in the cable duct. Note: Do not close any knife-type terminals or place the fuses back into the fuse terminals as long as no power is applied to all systems and not all signals have been checked for high voltages and short circuiting which may be caused by wiring faults in the field and/or junction boxes. These high voltages will damage the equipment of the FSC cabinet. The voltages and short circuiting need to be checked on the external devices. 5. Close all knife-type terminals and place back the fuses in the terminals used for the I/O wiring.
For detailed information on the exact location of the third-party devices refer to the general drawings, which are part of the project-related documentation. For detailed information on the FSC I/O modules connected to the third-party devices refer to the termination details, which are part of the project-related documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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Terminals maximum wire diameter Terminal wire strip length Terminal tightening torque
For detailed information on the maximum wire diameter refer to the data sheets of the applicable third-party device. For detailed information on the wire strip length refer to the data sheets of the applicable third-party device. For detailed information on the tightening torque refer to the data sheets of the applicable third-party device.
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3.7
Communication cables
3.7.1
Introduction
Cable types
The cables that enter the FSC cabinet can be divided into four different groups: Earth/grounding cables (see subsection 3.4), Power/feeder cables (see subsection 3.5), Field cables (see subsection 3.6), and Communication cables (see this subsection). Details on the requirements with regard to separation and routing of cables and wiring are provided in subsection 3.3.
Overview
The communication modules of the FSC system are placed in the Central Part(s). The communication interface boards of the FSC system are placed in the FSC cabinet. This is done in order to achieve easy access to the FSC cabinet for the external communication cables. The communication interface boards can be considered an extension of the communication modules. Taps are mounted in the FSC cabinet for the FSC-SMM communication with the Honeywell TotalPlant solution (TPS). External communication cables may be supplied with the FSC cabinet. These cables are used to establish communication between: Two or more FSC systems (FSC-FSC communication), FSC system and the FSC user station, FSC user station and a printer, FSC system and an FSCSOE PC, FSCSOE PC and a printer, FSC system and DCS system (Modbus communication), and FSC system and TPS system (FSC-SMM communication) (using taps). All cables are clearly tagged for easy identification and connection.
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The communication cables can be divided in three groups: Fiber optic cables, Tap trunk cables, and Other communication cables. The connection of each of these cable types is discussed in more detail in the following subsections. For detailed information on which cables should be connected refer to the communication drawings, which are part of the project-related documentation. For detailed information on the exact location of the taps and communication modules/interfaces refer to the general drawings, which are part of the project-related documentation.
3.7.2
Connecting fiber optic cables
Connecting fiber optic cables
There are three options for connecting fiber optic cables: Fiber optic modules (G-interface) are placed in the Central Part(s). Fiber optic converter modules are mounted in the FSC cabinet. A splice panel is mounted in the FSC cabinet. Each of these methods is discussed in more detail below.
Fiber optic modules in Central Part(s)
To connect the fiber optic cables to the fiber optic module (G-interface) placed in the Central Part, take the following steps: 1. Connect the fiber optic cable to the communication module located in the Central Part of the FSC cabinet. The cables are routed via the horizontal bus (H-Bus) mounted above the Central Part(s). 2. Clamp the fiber optic cable to the cable tray or cable duct mounted on the left-hand side of the FSC cabinet. Pay close attention to the following items: Make sure that sufficient slack is available in the fiber optic cable so that the swing frame can still be opened without tension on the cables. Check the specification of the fiber optic cable for the minimum bend diameter.
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3. Roll the fiber optic cable to the corresponding device. 4. Connect the fiber optic cable to the corresponding device. For detailed information on the exact location of the communication modules placed in the Central Part(s) refer to the rack layouts, which are part of the project-related documentation. For detailed information on the exact location of the fiber optic converter refer to the general drawings, which are part of the projectrelated documentation.
Considerations
If the fiber optic cables are to be connected to the communication modules placed in the Central Part(s), the following considerations should be noted: The transmitter signal and receive signal between two devices that use communication via fiber optic cables should be swapped. Provide a cable duct/tray to route the fiber optic cables to the level of the Central Part(s). This cable duct/tray should be mounted on the left hand side of the FSC cabinet. Check the specification of the fiber optic cable for the minimum bend radius. Make sure that the fiber optic cable can be routed in such a way that the bend radius in the cable will never be less than the specified minimum. Check the maximum allowable transmission loss. This is 23.5 dB for fiber optic communication between G interfaces mounted in the Central Parts. Check the minimum required transmission loss. This is 8 dB for fiber optic communication between G interfaces. To achieve the minimum required transmission loss, fiber optic dampers may need to be installed. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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Fiber optic converter module
To connect the fiber optic cables to the fiber optic converter module mounted in the FSC cabinet, take the following steps: 1. Connect the fiber optic cable to the fiber optic converter module mounted in the FSC cabinet. 2. Clamp the fiber optic cable to the cable tray or cable duct mounted next to the fiber optic converter module in the FSC cabinet. Pay close attention to the following items: Make sure that sufficient slack is available in the fiber optic cable. Check the specification of the fiber optic cable for the minimum bend diameter. 3. Roll the fiber optic cable to the corresponding device. 4. Connect the fiber optic cable to the corresponding device. For detailed information on the exact location of the fiber optic converter refer to the general drawings, which are part of the projectrelated documentation.
Considerations
If the fiber optic cables are to be connected to a fiber optic converter placed in the FSC cabinet, the following considerations should be noted: The transmitter signal and receive signal between two devices that use communication via fiber optic cables should be swapped. Provide a cable duct/tray to route the fiber optic cables to the fiber optic converters. Check the specification of the fiber optic cable for the minimum bend radius. Make sure that the fiber optic cable can be routed in such a way that the bend radius in the cable will never be less than the specified minimum. Check the maximum allowable transmission loss. Check the minimum required transmission loss. To achieve the minimum required transmission loss, fiber optic dampers may need to be installed. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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Splice panel
To connect the fiber optic cables to a splice panel mounted in the FSC cabinet, take the following steps: 1. Connect the fiber optic cable to the communication module located in the Central Part of the FSC cabinet. The cables are routed via the horizontal bus (H-Bus) mounted above the Central Part(s). 2. Clamp the fiber optic cable to the cable tray or cable duct mounted on the left-hand side of the FSC cabinet. Pay close attention to the following items: Make sure that sufficient slack is available in the fiber optic cable so that the swing frame can still be opened without tension on the cables. Check the specification of the fiber optic cable for the minimum bend diameter. 3. Roll the fiber optic cable to the splice panel mounted in the FSC cabinet. 4. Clamp the fiber optic cable to the cable tray or cable duct mounted next to the splice panel in the FSC cabinet. Pay close attention to the following items: Make sure that sufficient slack is available in the fiber optic cable. Check the specification of the fiber optic cable for the minimum bend diameter. 5. Connect the fiber optic cable to the connections in the splice panel. Check the project-related documentation for the connections. For detailed information on the exact location of the communication modules placed in the Central Part(s) refer to the rack layouts, which are part of the project-related documentation. For detailed information on the exact location of the splice panel refer to the general drawings, which are part of the project-related documentation. Please note that the transmitter signal and receive signal between two devices that use communication via fiber optic cables should be swapped. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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3.7.3
Connecting trunk cables to taps
Connection to taps
To connect the trunk cable to the taps, take the following steps: 1. Connect trunk cable A to tap A. 2. Connect trunk cable B to tap B. Use a torque wrench to ensure that the trunk cables are fastened with the correct torque. If you do not use a torque wrench, this might result in damaged cables and/or modules. For detailed information on which cables should be connected refer to the communication drawings, which are part of the project-related documentation. For detailed information on the exact location of the taps refer to the general drawings, which are part of the project-related documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
3.7.4
Connecting other communication cables
Connecting other communication cables
To connect the other communication cables, take the following steps: 1. Connect the plug to the corresponding communication module located in the FSC cabinet. 2. Fasten the screws of the cable connector to the communication module. 3. Clamp the communication cable to the cable tray or duct mounted next to the communication module using tire wraps. Pay close attention to the following items: If the communication cable is routed from the swing frame, make sure that the cable has sufficient slack. Check the specification of the communication cable for the minimum bend diameter. 4. Roll the communication cable to the corresponding device.
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5. Connect the plug to the corresponding connector in the corresponding device. 6. Fasten the screw of the cable connector to connector in the corresponding device. For detailed information on which cables should be connected refer to the communication drawings, which are part of the project-related documentation. For detailed information on the exact location of the communication modules refer to the general drawings, which are part of the projectrelated documentation. Note: Pay close attention to the requirements as described in subsection 3.3 with respect to separation and routing of cables and wiring.
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Section 4 Power-Up of the FSC Cabinet

This section provides information on powering up the FSC cabinet. It covers the following topics:
See page
Section overview
Subsection 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4
Topic
Section overview............................................................................................. 69 Checks prior to power-up................................................................................ 70 Checking all signal wiring ............................................................................... 70 Checking all incoming power .......................................................................... 70 Checking AC power ........................................................................................ 70 Checking DC power........................................................................................ 72 Performing the power-up ................................................................................ 73 Powering up a redundant system ................................................................... 73 Powering up a single system .......................................................................... 73 Troubleshooting .............................................................................................. 73 Activities after power-up ................................................................................. 74
It is recommended that the power-up of the FSC system is monitored by a Honeywell SMS representative who is familiar with the FSC system. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the installation, they can be solved on the spot. Powering up the FSC system consists of the following steps: Checks prior to power-up (see subsection 4.2): Check all signal wiring. Check all incoming power. Actual power-up of the FSC system (see subsection 4.3): Redundant, or Single. Each step is discussed in more detail in the following subsections.
Procedure
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4.2
Checks prior to power-up
4.2.1
Checking all signal wiring
Checking all signal wiring
Check all signal wiring to and from the FSC cabinet for high voltage levels and short circuiting (for outputs) as they may damage the electronic equipment of the FSC system. Checking all signal wiring can be skipped if this subsection is performed directly after connecting and checking the cables to the FSC system as described in Section 3 of this manual.
4.2.2
Checking all incoming power
Checking all incoming power
Before the power-up of the FSC system, all power supply units and/or external power supplied to the FSC cabinet need to be activated. AC and/or DC voltages may be supplied to the FSC cabinet(s).
4.2.3
Checking AC power
AC power
In order to ensure that all power supply units (PSUs) are operational, all PSUs need to be tested individually. The AC power/feeder cables should have been connected to the fuse terminals and/or main circuit breaker in accordance with subsection 3.5.4 of this manual. Before starting the test of the PSUs, check the following items in the FSC cabinet: All main circuit breakers should be off. All primary switches should be off. All secondary disconnectors should be off. All circuit breakers should be off.
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Section 4: Power-Up of the FSC Cabinet
Take the following steps for each AC/DC power supply unit (PSU) mounted in the FSC cabinet: 1. Remove the protective plate/cover from the main circuit breaker and/or fuse terminals inside the FSC cabinet. 2. Check the AC voltage on the incoming fuse terminals and/or main circuit breaker. 3. Check the PSU for correct input voltage. Note: If the incoming AC feeders do not meet the requirements as mentioned in the data sheets of the power supply units (PSUs), the FSC system should not be operated. 4. 5. 6. 7. Switch on the secondary disconnector of the PSU. Switch on the main circuit breaker of the PSU. Check the LED on the PSU (it should be on). Using a multimeter, measure the voltage on the main busbar or circuit breaker rack. 8. Switch off the main circuit breaker of the PSU. 9. Switch off the secondary disconnector of the PSU. 10. Put the protective plate/cover from the main circuit breaker and/or fuse terminals in the FSC cabinet back into place. For detailed information on the exact location of the fuse terminals, main circuit breaker, secondary disconnector, busbar and circuit breaker rack refer to the general drawings, which are part of the project-related documentation.
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4.2.4
Checking DC power
In order to ensure that all required external power is available, this needs to be tested individually for each feeder. The DC power/feeder cables should have been connected to the fuse terminals and/or main circuit breaker in accordance with subsection 3.5.6 of this manual. Before starting the test of the external power supply, check the following items in the FSC cabinet: All main circuit breakers should be off. All primary switches should be off. All secondary disconnectors should be off. All circuit breakers should be off. Take the following steps for each DC external power supply in the FSC cabinet individually: 1. Remove the protective plate/cover from the main circuit breaker and/or fuse terminals inside the FSC cabinet. 2. Check the DC voltage on the incoming fuse terminals and/or main circuit breaker. Note: If the incoming DC feeders do not meet the requirements as mentioned in subsection 3.5.5 of this manual, the FSC system should not be operated. 3. Place the fuses in the fuse terminals and/or switch on the main circuit breaker. 4. Using a multimeter, measure the voltage on the main busbar or circuit breaker rack. 5. Remove the fuses from the fuse terminals and/or switch off the main circuit breaker. 6. Place the required ferrites on each DC power/feeder cable (if not already installed in the FSC cabinet). For detailed information on ferrites refer Appendix F of this Service Manual. For detailed information on the exact location of the fuse terminals, main circuit breaker, and circuit breaker rack refer to the general drawings, which are part of the project-related documentation.
DC power
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4.3
Performing the power-up
4.3.1
Powering up a redundant system

It is recommended that the power-up of the FSC system is monitored by a Honeywell SMS representative who is familiar with the FSC system. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the installation, they can be solved on the spot. The power-up of an FSC system with redundant Central Parts must be performed in accordance with the procedure as described in Appendix C of this Service Manual.
Powering up a redundant system
4.3.2
Powering up a single system

It is recommended that the power-up of the FSC system is monitored by a Honeywell SMS representative who is familiar with the FSC system. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the installation, they can be solved on the spot. The power-up of an FSC system with a single Central Part must be performed in accordance with the procedure as described in Appendix C of this Service Manual.
Powering up a single system
4.3.3
Troubleshooting
It is possible that alarm/error messages are generated during the power-up of the FSC system. For an explanation of the most common alarms/error generated during the power-up of the FSC system refer to Appendix D of this manual. For more information on the alarms/error messages generated by the FSC system refer to the FSC Software Manual.
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4.3.4
Activities after power-up
After the power-up
After power-up of the FSC system, the three-monthly preventive maintenance tasks should always be carried out. For details refer to Section 7 of this Service Manual.
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Section 5 Site Acceptance Test

This section provides general information on the Site Acceptance Test (SAT) to be performed on the FSC cabinet.
See page
Section overview
Subsection 5.1 5.2 5.3 5.4 5.5
Topic
Section overview............................................................................................. 75 SAT definition and objective ........................................................................... 76 Involved parties............................................................................................... 77 Documentation required ................................................................................. 77 Contents of the SAT document ...................................................................... 79
Start
At this point, the power-up of the FSC cabinet as described in Section 4 of this manual should have been completed successfully.
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5.2
SAT
SAT definition and objective

The Site Acceptance Test (SAT) is a test that may be performed after the FSC cabinet has been transported to site, installed and powered up. The aim of the SAT is to show to the customer/end user that the delivered FSC cabinet is operational and in good condition. HSMS has a standard SAT document which can be used as a reference document during the SAT. During the SAT, the FSC cabinet will be checked for several items, including any outstanding issues mentioned in the Factory Acceptance Test (FAT) document (only if an FAT was performed). Once the customer/end used has accepted the FSC cabinet by signing the release note attached to the SAT document, the loop check, start-up of the process and commissioning activities can be started. It is possible that customer/end users have their own release notes for the official acceptance of the FSC cabinet after the SAT. It is possible that an SAT is not requested by the customer/end user. In that case the signing of the release note attached to the FAT document is the official acceptance by the customer/end user. Here, too, it is possible that customers/end users have their own release note for the official acceptance of the FSC cabinet after the FAT.
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Section 5: Site Acceptance Test
5.3
Involved parties
As a minimum, the following representatives should be involved to perform the SAT on the FSC cabinet: End user or representative of the end user, Customer (if not end user) or customer representative, and Honeywell SMS representative.
Who should be involved?
5.4
Documentation required
The documentation required for the SAT on the FSC system can be split into two sections: Project-related documentation, and FSC user documentation. Each of these sections is discussed in more detail below.
Documentation
Project-related documentation
Every FSC cabinet is supplied with project-related documentation which provides detailed information and guidelines for the specific FSC cabinet(s). The following information may be included for a cabinet: General drawings, Power consumption calculation / heat dissipation calculation, Rack layout, Termination details, Power distribution, Communication overview, Functional Logic Diagrams (FLDs), Engineering documents, Factory Acceptance Test (FAT) document, and Site Acceptance Test (SAT) document. The above-mentioned documentation will always relate to one or more specific FSC cabinets.
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Note: Always make sure that the latest versions of the project-related documentation is available. This is not necessarily the "as-built" documentation. If you work with old and/or obsolete documentation, this may lead to problems and/or delays during maintenance, service and modification.
FSC user documentation
There is also generic user documentation that applies to all FSC systems. This documentation provides technical details of the FSC hardware modules as well as user manuals for the FSC user software. The following manuals are available: FSC Hardware Manual. This is the technical catalog containing descriptions and technical specifications of the FSC hardware modules and components. FSC Software Manual. This is the user manual to the FSC Navigator software, which is used to interface with the FSC system. FSC Safety Manual. This is a document which provides general information on safety and safety-related systems, as well as implementation guidelines for FSC systems. FSC-SM documentation set. This is a set of manuals that provide information and guidelines for the implementation of the FSC Safety Manager (FSC-SM). Notes: 1. All references in this Service Manual made to the FSC Hardware Manual refer to the latest version of this document. 2. All references in this Service Manual made to the FSC Software Manual refer to Release 510 and higher. 3. All references in this Service Manual made to the FSC Safety Manual refer to Release 510 and higher. 4. All references in this Service Manual made to the FSC-SM documentation refer to the latest version of this documentation.
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5.5
Contents of the SAT document

HSMS has a standard SAT document which can be used as a reference document during the SAT. During the SAT, the items mentioned in this document should be checked as a minimum. These include: Check of documentation availability, Mechanical installation, Visual check and spot-check of the wiring, and Check of communication links to external systems and peripherals. However, the SAT does not need to be limited to the checks mentioned above or in the standard HSMS SAT document.
SAT document
Obtaining the SAT document
For information on how to obtain the standard HSMS SAT document you can contact your local Honeywell representative.
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Section 6 General Maintenance Considerations

This section provides general information on maintenance tasks that may need to be performed on the FSC cabinets. It covers the following topics:
See page
Section overview
Subsection 6.1 6.2 6.3 6.4 6.5 6.6
Topic
Section overview............................................................................................. 81 Types of maintenance .................................................................................... 82 Corrective maintenance.................................................................................. 83 Actions before maintenance, service and modification .................................. 84 Actions during maintenance, service and modification .................................. 86 Actions after maintenance, service and modification ..................................... 87
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6.2
Types of maintenance
Maintenance performed on the FSC cabinet can be split into four main sections: Preventive maintenance (see Section 7), Troubleshooting and fault-finding (see Section 8), Service and/or modifications to the FSC cabinet (see Section 9), and Corrective maintenance (see subsection 6.3).
Maintenance types
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Section 6: General Maintenance Considerations
6.3
Corrective maintenance
Corrective maintenance must be performed after the FSC system has generated an alarm or detected an error. Depending on the alarm or error reported, certain modules may need to be replaced. The replacement procedures for all FSC modules are described in the FSC Maintenance & Replacement Guide (document FS99-505). Contact your local Honeywell representative for details on how to obtain this document. Important! An alarm/error message generated by the FSC system requires immediate attention and action. Ignoring an FSC alarm/error message may cause severe damage to the equipment and/or serious injury to people. Important! Replacement of any equipment inside the FSC cabinet must be carried out with the utmost care, and by authorized and qualified persons only. In case of errors or mistakes during the replacement of certain modules, the FSC system can go to a safe state resulting in a process shutdown.
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6.4
Actions before maintenance, service and modification

Depending on the tasks to be performed on the FSC cabinet, a number of actions need to be taken before any maintenance, service or modification to the FSC cabinet is carried out. These actions are required to ensure that the work on the FSC cabinet is performed without any problems and within the given time frame. These actions may include (but need not be limited to): Checking that the spare parts are of the correct type (check module and suffix numbers), Checking the tools, Contacting the operator, Organizing other parties (if any), and Arranging and checking permits. Each of these items is discussed in more details below. Note: The above-mentioned items are recommended by Honeywell SMS. Where applicable, customer/plant procedures may override them or demand additional actions.
Before work on FSC cabinet
Checking spare parts
Make sure that the spare modules are of the correct type. This can be checked by verifying the module numbers and, where applicable, suffix numbers. This information can be found at the front of each module. If the module number and/or suffix number of the spare module do not match, do NOT proceed with the replacement of the faulty module. Note: It is essential that the availability of spare parts is checked on a regular basis to avoid any problems when they are urgently needed. For details refer to Section 7 of this Service Manual.
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Checking tools
Before starting any maintenance, service and modification to the FSC cabinet, make sure that the tools required are in order. As a minimum, the following tools are required: FSC user station (including all required software), 07170/1/1 EPROM programmer (depending on FSC system configuration), EPROM eraser (depending on FSC system configuration), EPROM remover (depending on FSC system configuration), Spare EPROMs (depending on FSC system configuration), 3-digit multimeter(voltage, current, and resistance), Pliers/spanners, Set of screwdrivers (both flatblade and Phillips), Torque wrench for connecting trunk/drop cables (depending on FSC system configuration), Several pairs of tongs, and Set of spanners (10 mm, 12 mm, 13 mm, 14 mm, etc.).
Contacting the operator
Make sure that the operator is contacted before the start of any maintenance, service and modification. The operator will be able to determine if it acceptable to perform the maintenance, service and modification at that point in time. Assistance from any other parties may be required during the maintenance, service and modification to FSC cabinets. Make sure that all parties required are contacted and that all arrangements are made. Make sure that all permits required to perform the maintenance, service and modification to the FSC cabinet are available and signed by the appropriate responsible parties.
Organizing other parties
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6.5
Actions during maintenance, service and modification

Depending on the tasks to be performed on the FSC cabinet, a number of actions need to be taken while maintenance, service or modification to the FSC cabinet is being carried out. These actions are required to ensure that the work on the FSC cabinet is performed without any problems and within the given time frame. These actions may include (but need not be limited to): Contacting the operator, and Contacting other parties (if any). Each of these items is discussed in more details below. Note: The above-mentioned items are recommended by Honeywell SMS. Where applicable, customer/plant procedures may override them or demand additional actions.
During work on FSC cabinet
Contacting the operator Contacting other parties
Make sure that the operator is kept informed on the progress of the maintenance, service and modification work performed. Make sure that any other parties involved are kept informed on the progress of the maintenance, service and modification work performed.
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6.6
Actions after maintenance, service and modification

Depending on the tasks to be performed on the FSC cabinet, a number of actions need to be taken after any maintenance, service or modification to the FSC cabinet has been carried out. These actions are required to ensure that the work on the FSC cabinet is performed without any problems and within the given time frame. These actions may include (but need not be limited to): Contacting the operator, Taking care of permits, and Making sure that defective items are repaired. Each of these items is discussed in more details below. Note: The above-mentioned items are recommended by Honeywell SMS. Where applicable, customer/plant procedures may override them or demand additional actions.
After work on FSC cabinet
Contacting the operator Permits
Make sure that the operator is informed that the maintenance, service and modification has been completed successfully. Make sure that all permits that were required to perform the maintenance, service and modification are signed and returned to the appropriate responsible parties. If during maintenance, service and modification items have been replaced of removed from the FSC cabinet, these need to be checked for their functionality. For the FSC Central Part and I/O modules this can be done using an FSC simulation/training unit. If any items are found to be defective, they can be returned to HSMS for further investigation into the cost of repair. For details on how to return defective items refer to Appendix G of this Service Manual.
Repair defect items
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Section 7 Preventive Maintenance

This section provides information on the preventive maintenance that needs to be performed regularly on the FSC cabinets. It covers the following topics:
See page
Section overview
Subsection 7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.4.8 7.4.9 7.4.10 7.4.11 7.4.12 7.4.13
Topic
Section overview............................................................................................. 89 Preventive maintenance overview.................................................................. 90 Three-monthly preventive maintenance ......................................................... 91 Overview ......................................................................................................... 91 Checking the voltages to the Central Part ...................................................... 91 Checking the temperatures in the Central Part .............................................. 96 Checking air flow obstruction.......................................................................... 98 Checking the correct operation of the fans..................................................... 98 Checking for earth faults................................................................................. 99 Checking the loop status of signals .............................................................. 101 Checking the forced status of signals........................................................... 103 Checking for paint damage........................................................................... 104 Checking the availability of spare parts ........................................................ 104 Checking the system diagnostics ................................................................. 105 Checking the backup of the application files ................................................ 106 Preventive maintenance during every power-down ..................................... 107 Overview ....................................................................................................... 107 Checking all DC voltages.............................................................................. 108 Checking the power distribution fuses.......................................................... 109 Checking the AC voltages ............................................................................ 110 Checking the correct operation of the PSUs ................................................ 111 Checking for dust concentration ................................................................... 112 Replacing all dust filters................................................................................ 112 Checking the fasteners on the power distribution rails................................. 113 Checking all cable clamps ............................................................................ 113 Checking all shield connections ................................................................... 114 Checking all earth/ground connections ........................................................ 115 Testing all hardware I/O................................................................................ 116 Testing all communication links to external devices..................................... 118
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7.2
Preventive maintenance overview

Preventive maintenance is necessary to prevent faults in the FSC cabinet. It is concentrated on the most sensitive elements in the FSC cabinet. The preventive maintenance that should be carried out can be split into two major components: Three-monthly preventive maintenance (see subsection 7.3), and Preventive maintenance during every power-down (see subsection 7.4).
Preventive maintenance
Checklists
Refer to Appendix E for checklists on the items to be performed during preventive maintenance. This allows you to keep a record and retrieve information if any problems should arise. The checklists consist of five sections: General information (information on customer, plant, FSC cabinet, etc.), FSC configuration items (information on software version, application version, power-on mode, etc.), FSC system information (information on Central Part voltages and temperature sensors in the Central Part), Items to be checked during preventive maintenance, and Acceptance of checklist (signed by both the customer representative and Honeywell representative).
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Section 7: Preventive Maintenance
7.3
Three-monthly preventive maintenance
7.3.1
Overview
The following maintenance items need to be performed every three months: Checking the voltages to the Central Part (see subsection 7.3.2), Checking the temperatures in the Central Part (see subsection 7.3.3), Checking for any obstruction of air flow (see subsection 7.3.4), Checking the correct operation of the fans (see subsection 7.3.5), Checking for earth faults (if an earth fault detection device is available) (see subsection 7.3.6), Checking the loop status of signals (see subsection 7.3.7), Checking the forced status of signals (see subsection 7.3.8). Checking for paint damage (see subsection 7.3.9), Checking the availability of spare parts (see subsection 7.3.10), Checking the extended diagnostics of the system (see subsection 7.3.11), and Checking the backup of the application files (see subsection 7.3.12).
Every three months
7.3.2
Checking the voltages to the Central Part

Each Central Part of an FSC cabinet contains a power supply unit (HSMS type 10300/x/x) which converts the incoming 24 Vdc to 5 Vdc and supplies that to the Central Part modules and I/O modules. The voltages to the Central Part which are generated by the PSU can be checked in either of two ways: via the display of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x), or via the FSC Navigator user software. For technical details on the 10006/x/x Diagnostic and Battery Module and the 10300/x/x DC/DC converter refer to the FSC Hardware Manual.
Voltages on the Central Part
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For details on the module locations in the Central Part racks refer to the rack layout drawings, which are part of the project-related documentation. Checking via the DBM
The following information can be retrieved from the DBM display: Supply voltage from the 10300/x/x DC/DC converter, and DBM battery voltage.
Supply voltage from 10300/x/x
The voltage generated by the 10300/x/x DC/DC converter should be within the levels specified below. If the voltage is outside that range, the Central Part will stop. To check the voltage of the 10300/x/x DC/DC converter, take the following steps: 1. A 10006/x/x Diagnostic and Battery Module (DBM) is placed in each of the Central Parts in the FSC cabinet. Its exact location in the rack can be obtained from the rack layout drawings, which are part of the project-related documentation. 2. Push the switch on the DBM upward four times. The display of the DBM will now show the voltage generated by the 10300/x/x DC/DC converter of the corresponding Central Part. 3. The voltage displayed should be between 4.75 Vdc and 5.25 Vdc. If it is not, the 10300/x/x DC/DC converter needs to be recalibrated. This requires the 10300/x/x module to be returned to Honeywell SMS. (Refer to Appendix G of this Service Manual for details on how to proceed.) 4. You can return to the default display (current time) by moving the DBM switch downward four times. Alternatively, you can wait for about 30 seconds. The display will then automatically return to the time display. The above check needs to be performed for each Central Part in the FSC cabinet.
DBM battery voltage
Batteries are mounted on the 10006/x/x Diagnostic and Battery Module (DBM) which provide the backup power for the RAM memory on the Central Processing Unit (CPU) and communication (COM) modules. If the FSC system is running in RAM mode and the 24 Vdc to the Central Part is disconnected, these batteries will ensure that the information stored in the RAM chips is retained. When fully charged, the batteries provide sufficient power to ensure that the data in the RAM chips is retained for three months.
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Note: If the cabinet temperature exceeds 50C (122F) for an extended time period (>24 hours), the batteries may be damaged and lose their power backup capabilities. When a new DBM is supplied, a jumper needs to be set before the batteries are actually charged. For details on the jumper setting of the DBM module refer to the module data sheet in the FSC Hardware Manual. To check the voltage of the batteries mounted on the DBM, take the following steps: 1. A 10006/x/x Diagnostic and Battery Module (DBM) is placed in each of the Central Parts in the FSC cabinet. Its exact location in the rack can be obtained from the rack layout drawings, which are part of the project-related documentation. 2. Push the switch on the DBM upward five times. The display of the DBM will now show the charge voltage level of the backup batteries. 3. The voltage displayed should be higher than 4.05 Vdc. If it is not, the batteries on the DBM should be replaced. For detailed information on how to replace the batteries refer to the DBM data sheets in the FSC Hardware Manual. DBM modules with a suffix code lower than 08802 do not have exchangeable batteries. Should the batteries of these modules need to be replaced, the DBM module must be returned to Honeywell SMS. (Refer to Appendix G of this Service Manual for details on how to proceed.) 4. You can return to the default display (current time) by moving the DBM switch downward five times. Alternatively, you can wait for about 30 seconds. The display will then automatically return to the time display. The above check needs to be performed for each Central Part in the FSC cabinet. Note: It is recommended that the batteries mounted on the DBM module are replaced every four years. For details on how to replace the batteries refer to the DBM data sheet in the FSC Hardware Manual.
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Checking via FSC Navigator
The following information can be retrieved when using the FSC Navigator user software: Battery voltage of the S-Bus, Battery voltage of the DBM, and Supply voltage from the 10300/x/x DC/DC converter. To retrieve this information, take the following steps: 1. Start FSC Navigator. 2. In the On-Line Environment screen, click the Diagnostics button. A drop-down menu will open. 3. From the drop-down menu, choose the 'System Information' option. 4. Choose the 'Read DBM status' option. (Please note that this menu option will only be available if a DBM module has been placed in the FSC cabinet.) The screen as shown in Figure 7-1 below will appear. This screen is for information purposes only. You cannot edit anything in this screen. The information displayed is updated continuously.
Figure 7-1 Status of Diagnostic and Battery Module (DBM)

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Battery voltage S-Bus
This is the voltage level of the bus that the DBM is connected to. This voltage is typically between 0.15 Vdc and 0.35 Vdc lower than the voltage generated by the 10300/x/x DC/DC converter. This is due to the diode on the rear of the S-Bus. If the difference is minimal, this indicates that the diode on the rear of the S-Bus has failed. Batteries are mounted on the 10006/x/x Diagnostic and Battery Module (DBM) which provide the backup power for the RAM memory on the Central Processing Unit (CPU) and communication (COM) modules. If the FSC system is running in RAM mode and the 24 Vdc to the Central Part is disconnected, these batteries will ensure that the information stored in the RAM chips is retained. When fully charged, the batteries provide sufficient power to ensure that the data in the RAM chips is retained for three months. Note: If the cabinet temperature exceeds 50C (122F) for an extended time period (>24 hours), the batteries may be damaged and lose their power backup capabilities. When a new DBM is supplied, a jumper needs to be set before the batteries are actually charged. For details on the jumper setting of the DBM module refer to the module data sheet in the FSC Hardware Manual. The voltage displayed should be higher than 4.05 Vdc. If it is not, the batteries on the DBM should be replaced. For detailed information on how to replace the batteries refer to the DBM data sheets in the FSC Hardware Manual. DBM modules with a suffix code lower than 08802 do not have exchangeable batteries. Should the batteries of these modules need to be replaced, the DBM module must be returned to Honeywell SMS. (Refer to Appendix G of this Service Manual for details on how to proceed.) For technical details on the 10006/x/x Diagnostic and Battery Module (including the jumper settings) refer to the FSC Hardware Manual. For details on the module locations in the Central Part racks refer to the rack layout drawings, which are part of the project-related documentation.
Battery voltage of DBM
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Note: It is recommended that the batteries mounted on the DBM module are replaced every four years. For details on how to replace the batteries refer to the DBM data sheet in the FSC Hardware Manual.
Supply voltage from 10300/x/x
The voltage generated by the 10300/x/x DC/DC converter should be between 4.75 Vdc and 5.25 Vdc. If the voltage is outside this range, the Central Part will stop. The 10300/x/x DC/DC converter will then need to be recalibrated. This requires the 10300/x/x module to be returned to Honeywell SMS. (Refer to Appendix G of this Service Manual for details on how to proceed.)
7.3.3
Checking the temperatures in the Central Part

Temperature sensors are mounted on the Diagnostic and Battery Modules (DBM HSMS type 10006/x/x) which allow the temperatures in the Central Part to be monitored. The following temperature setting are specified during the system configuration of the FSC system: Low temperature alarm, Low temperature shutdown, High temperature alarm, and High temperature shutdown. If the temperature detected by the DBM sensors goes below the low temperature alarm setpoint or exceeds the high temperature alarm setpoint, an alarm will be generated. If the temperature detected by the DBM sensors goes below the low temperature shutdown setpoint or exceeds the high temperature shutdown setpoint, the affected Central Part of the FSC system will automatically stop. The temperature sensors mounted in the DBM can be checked in either of two ways: via the display of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x), or via the FSC Navigator user software. For technical details on the 10006/x/x Diagnostic and Battery Module and the 10300/x/x DC/DC converter refer to the FSC Hardware Manual.
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For details on the module locations in the Central Part racks refer to the rack layout drawings, which are part of the project-related documentation. Checking via the DBM To check the temperature sensors in the FSC cabinet, take the following steps: 1. A 10006/x/x Diagnostic and Battery Module (DBM) is placed in each of the Central Parts in the FSC cabinet. Its exact location in the rack can be obtained from the rack layout drawings, which are part of the project-related documentation. 2. Push the switch on the DBM upward two times. The display of the DBM will now show the temperature measured by the first sensor. 3. Push the switch on the DBM upward one more time. The display of the DBM will now show the temperature measured by the second sensor. 4. You can return to the default display (current time) by moving the DBM switch downward three times. Alternatively, you can wait for about 30 seconds. The display will then automatically return to the time display. 5. Check that the temperatures displayed on the DBM are not close to the temperature setpoint specified in the FSC system configuration (Install / Modules / Central parts / DBM). If the temperatures are close to the defined setpoints, check the operation of the air-conditioning and fans, and make sure the filters are not obstructed. The above check needs to be performed for each Central Part in the FSC cabinet. Checking via FSC Navigator To check the temperature sensors of the DBM, take the following steps: 1. Start FSC Navigator. 2. In the On-Line Environment screen, click the Diagnostics button. A drop-down menu will open. 3. From the drop-down menu, choose the 'System Information' option. 4. Choose the 'Read DBM status' option. (Please note that this menu option will only be available if a DBM module has been placed in the FSC cabinet.) The screen as shown in Figure 7-1 on page 94 will appear. This screen is for information purposes only. You cannot edit anything in this screen. The information displayed is updated continuously.
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The 'Temperature 1' field displays the temperature measured by the first sensor, and the 'Temperature 2' field the temperature measured by the second sensor. Check that the temperatures displayed on the DBM are not close to the temperature setpoint specified in the FSC system configuration (Install / Modules / Central parts / DBM). If the temperatures are close to the defined setpoints, check the operation of the air-conditioning and fans, and make sure the filters are not obstructed. The above check needs to be performed for each Central Part in the FSC cabinet.
7.3.4
Checking air flow obstruction
Air flow obstruction
Most FSC cabinets have one or more fans in the roof and filters in the door. This establishes a forced air circulation inside the FSC cabinet. To ensure correct air flow, check the following items: Check for any obstruction of the fan(s). This might lead to malfunctions of the fan(s) or other dangerous situations. Check for any obstructions of the filter(s). In normal situations the air enters the cabinet via the filters. If the filters are obstructed, false air with more dust particles may enter the FSC cabinet. The dust particles may cause malfunctioning of the equipment.
7.3.5
Checking the correct operation of the fans
Fan operation
All fans should be operational. If one or more fans in an FSC cabinet have failed, the temperature inside the FSC cabinet will rise. If the temperature detected by the DBM sensors goes below the low temperature shutdown setpoint or exceeds the high temperature shutdown setpoint, the affected Central Part of the FSC system will automatically stop. To check all fans, take the following steps: 1. Check whether all fans are functioning properly. 2. If a fan has failed, check the fuse or circuit breaker installed in the FSC cabinet.
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3. If a fuse has blown, replace this fuse. Make sure that the new fuse has the correct measurements and rating. If the fuse blows instantly, there are two options: The fan is faulty and needs to be replaced. There is a short circuit in the wiring. Use a multimeter to measure the resistance of the wiring. 4. If a circuit breaker has switched off, activate this circuit breaker again. If the circuit breaker is deactivated instantly, there are three options: The circuit breaker is faulty and needs to be replaced. Make sure that the new circuit breaker has the correct rating. The fan is faulty and needs to be replaced. There is a short circuit in the wiring. Use a multimeter to measure the resistance of the wiring. For details on the rating of the fuse or circuit breaker refer to the power distribution drawings, which are part of the project-related documentation. For details on the exact locations of the fuses and/or circuit breakers refer to the general drawings, which are part of the project-related documentation.
7.3.6
Checking for earth faults
Earth faults
This test only needs to be performed if earth leakage detection (ELD) devices are present in the FSC cabinet. There are two types of ELDs: 10310/1/1 (rail-mounted unit), and 10310/2/1 (rack-mounted unit). A flashing green "Mode" LED indicates that the ELD is operational. A red "Fault" LED indicates that an earth fault has been detected. Move the switch on the ELD to the "RESET" position. If the red LED remains on, the earth fault still exists and should be resolved (see the next page). Verify the correct operation of the ELD by checking the auxiliary contact of the ELD. The auxiliary contact of the ELD is normally wired to a digital input module in the FSC cabinet or to terminals for external use. Under normal conditions (i.e. no earth fault detected), the digital input should be high. If wired to terminals, the contact on these terminals should be closed. (This should be checked on the external
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device.) After testing the correct operation of the ELD, use the "Reset" switch at the front of the ELD to reset the module. The correct operation of the ELD can only be tested if no earth fault is present. To test the ELD, take the following steps: 1. Move the bottom switch on the ELD to the "TEST" position. The red "Fault" LED should start flashing. 2. Move the bottom switch on the ELD to the "RESET" position. The red "Fault" LED should go off. To see if a 10310/x/x ELD has been installed, check the power distribution drawings, which are part of the project-related documentation. For details on the exact location of the 10310/1/1 ELD, if it is present, refer to the general drawings, which are part of the project-related documentation. For details on the exact location of the 10310/2/1 ELD, if it is present, refer to the rack layout drawings, which are part of the project-related documentation. How to solve earth faults The procedure to trace an earth fault is identical for both types of earth leakage detectors. The following equipment is required to trace an earth fault: a current clamp (e.g. the DCM300E digital clamp from AVO International), and a voltmeter with a 200 mVac range. If the clamp is placed on a cable in which no earth fault is present, the voltmeter will display a steady value. If the clamp is placed on a cable with an earth fault, the signal will pulse due to the frequency generated by the ELD. Please note that the frequency and signal value of the ELD is very small compared to, for example, a 50 Vac/50 Hz signal. To trace the earth fault, take the following steps: 1. Check if the earth fault still exists. A red "Fault" LED indicates that an earth fault has been detected. Move the switch on the ELD to the "RESET" position. If the red LED remains on, the earth fault is still there. 2. Make sure the top switch of the ELD is in the '1/4 Hz' position. 3. Connect the current clamp to the voltmeter.
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4. Place the clamp around the top cable loom which goes from the swing frame to the rear of the FSC cabinet. 5. Wait for 8 seconds to see if the signal on the voltmeter is pulsing. If the clamp is removed too soon, no earth fault will be detectable. 6. If no earth fault is detected, take the next cable loom. Repeat this step until the earth fault is detected. The rack number in which the earth fault is present is then known. 7. Check each single SIC cable at the rear of the I/O rack until the earth fault has been located. 8. Once you know the affected module, you can identify the corresponding FTA using the termination details. 9. Locate the FTA and check each individual signal pair connected to the FTA until you have located the earth fault. 10. The cause of the earth fault is most likely located at the field device. 11. Move the bottom switch on the ELD to the "RESET" position. If the red LED remains on, another earth fault exists. 12. Repeat the above steps until all earth fault have been resolved.
7.3.7
Checking the loop status of signals
Loop status of signals
To retrieve information on the loop status of the signals, take the following steps: 1. Start FSC Navigator. 2. In the On-Line Environment screen, click the Diagnostics button. A drop-down menu will open. 3. From the drop-down menu, choose the 'I/O Loop Diagnostics' option. This will open the screen as shown in Figure 7-2 on the next page, which lists the I/O loop diagnostics for the entire application (i.e. both Central Parts in a redundant system):
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Figure 7-2 Viewing the I/O loop status The screen displays the following: the specification (type, tag number, location) of all analog input channels whose values are out of their defined range, all output variables allocated to a 10216/2/1 (24 Vdc digital output module with line-monitoring capabilities) or 10216/2/3 module (48 Vdc digital output module with line-monitoring capabilities) that have an open loop or short circuit, and all variables allocated to a 10106/2/1 module (digital input module with line-monitoring capabilities) whose loop status is not OK. For technical details on the above modules refer to the FSC Hardware Manual. All signals that are reported faulty should be checked and solved.
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7.3.8
Checking the forced status of signals
Forced status of signals
You should also check whether the signals that are forced in the FSC system still need to be forced. To retrieve information on the forced signals, take the following steps: 1. Start FSC Navigator. 2. In the On-Line Environment screen, click the Process Status Monitoring button. A drop-down menu will open. 3. From the drop-down menu, choose the 'List Forces' option. This will open a screen which lists all variables in the FSC system that are currently forced (analog/digital inputs, analog/digital outputs, and markers) (see Figure 7-3 below).
Figure 7-3 Listing all forces in the system The variables are represented by their rack, position, channel, type and tag number. If no variables are forced, a message will be displayed. If the list does not fit on the screen, you can use the arrow keys on the keyboard to scroll through the list. Check whether the signals listed still need to be forced. Make sure that you contact the operators to verify this.
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7.3.9
Checking for paint damage
Paint damage
You should regularly inspect the FSC cabinet for paint damage. If you detect any paint damage, you should immediately touch up the damaged spots. This is the only way to prevent corrosion of the FSC cabinets. The standard colors used are: RAL 7032 (kieselgrau / pebble gray). Used for the cabinet enclosure. RAL 7022 (umbaugrau / dark gray). Used for the plinth. Depending on customer requirements, it is possible that different colors are used.
7.3.10
Checking the availability of spare parts
Spare parts
To avoid any problems with spare parts when they are urgently needed, it is essential that you check their availability: Check if sufficient spare parts are available. Used parts should be replaced. Check if additional spare parts are required (e.g. because a new FSC system was delivered). If desired, Honeywell SMS may also be asked to test the spare parts. For further details about this option please contact your local Honeywell representative.
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7.3.11
Checking the system diagnostics
Diagnostics
The system diagnostics provide valuable information on the system status. In order to guarantee problem-free operation of the FSC system, it is essential that you regularly check the system diagnostics. You can check the system diagnostics using the FSC Navigator software (running on an FSC user station connected to the FSC system). If you choose the "Extended Diagnostics" option in the On-Line menu of FSC Navigator, all diagnostic messages from the current application are retrieved from the system and displayed on screen (see Figure 7-4 below). If there are no errors, this will be reported as well.
Figure 7-4 Checking the system diagnostics Important! An alarm/error message generated by the FSC system requires immediate attention and action. Ignoring an FSC alarm/error message may cause severe damage to the equipment and/or serious injury to people.
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If there are any error messages, the following information is displayed on screen: module name, short description of the event, rack and position of hardware modules, and time and date of event. For details on working with system diagnostics refer to Section 12 of the FSC Software Manual ("On-Line Environment"). For details on how to act on reported messages refer to Section 8 of this manual ("Troubleshooting and Fault-Finding").
7.3.12
Checking the backup of the application files

It is important that you always have a backup of the application files in your project directory. The project directory is a subdirectory of the FSC application directory (C:\FSC by default). The name of the directory is identical to the project name. Thus, if you have a project called 'PROJ', the corresponding project files will be located in a subdirectory called 'PROJ' (usually C:\FSC\PROJ\). Make sure that the backup comprises the most recent version of the application. If that is not the case, make a backup of all files in the project directory for backup. This ensures that the diagnostic information from the FSC system (obtained using the "Extended Diagnostic" option) is also included. These files can then be viewed off-line at a later stage using the FSC Navigator software. It is recommended that you use removable storage media for your backup (e.g. floppy disk, CD-R, or ZIP disk).
Application files
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7.4
Preventive maintenance during every power-down
7.4.1
Overview
Every power-down
The following maintenance items need to be performed during every power-down of the plant/process: All items that need to be checked every three months (see subsection 7.3, Checking all other DC voltages (see subsection 7.4.2), Checking the power distribution fuses (see subsection 7.4.3), Checking all AC voltages (see subsection 7.4.4), Checking the correct operation of the PSUs (see subsection 7.4.5), Checking for dust concentration in the FSC cabinet (see subsection 7.4.6), Replacing all dust filters (see subsection 7.4.7), Checking the fasteners on the power distribution rails (see subsection 7.4.8), Checking all cable clamps (see subsection 7.4.9), Checking all shield connections (see subsection 7.4.10), Checking all earth/ground connections (see subsection 7.4.11), Checking all hardware I/O (see subsection 7.4.12), and Checking all communication links to external devices (see subsection 7.4.13). The next subsections discuss all items that were not explained in subsection 7.3.
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7.4.2
Checking all DC voltages
DC voltages
All DC voltages in the FSC cabinet should be within certain levels. If they are outside their range, the Central Part will stop. The DC voltages can be split into two types: Voltages that are supplied externally, and Voltages generated by power supply units in the FSC cabinet. Each of these items is discussed in more detail below.
High voltages
Equipment with high voltages (i.e. above 40 Vdc or 30 Vac) are covered by a protective plate or cover. If these voltages are connected, take extra precautions when the protective plates/covers are removed. After checking the voltages, make sure that you put the protective plates/covers back into place. To check all DC voltages that are supplied externally, take the following steps: 1. Use a multimeter to measure the DC voltages on the incoming fuse terminals and/or main circuit breakers located in the FSC cabinet. 2. The voltages should be within the following ranges: 110 Vdc: +25% / 15% 60 Vdc: +15% / 15% 48 Vdc: +15% / 15% 24 Vdc: +30% / 15% It is recommended that the incoming 24 Vdc voltage be adjusted to 25 Vdc (identical to the approved Delta power supply units supplied by HSMS). This is to ensure that the voltage at the modules will always be in accordance with requirements, taking into account the voltage drop in the FSC cabinet. For details on the exact locations of the fuse terminals and/or main circuit breakers refer to the general drawings, which are part of the project-related documentation. For details on the voltages that apply to specific FSC cabinets refer to the power distribution drawings, which are part of the project-related documentation.
Externally supplied voltages
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Voltages generated by PSUs
To check all DC voltages generated by power supply units (PSUs) in the FSC cabinet, take the following steps: 1. Use a multimeter to measure the DC voltages on the busbar or circuit breaker rack located in the FSC cabinet. 2. The voltages should be within the following ranges: 110 Vdc: +25% / 15% 60 Vdc: +15% / 15% 48 Vdc: +15% / 15% 24 Vdc: +30% / 15% It is recommended that the incoming 24 Vdc voltage be adjusted to 25 Vdc (identical to the approved Delta power supply units supplied by HSMS). This is to ensure that the voltage at the modules will always be in accordance with requirements, taking into account the voltage drop in the FSC cabinet. For details on the exact locations of the busbars and/or circuit breaker rack refer to the general drawings, which are part of the project-related documentation. For details on the voltages that apply to specific FSC cabinets refer to the power distribution drawings, which are part of the project-related documentation.
7.4.3
Checking the power distribution fuses
Power distribution fuses
If separate power supply unit cabinets are supplied, it is possible that fuses are installed in the power distribution between the cabinets. To check the power distribution fuses, take the following steps: 1. Check whether a fuse has blown. 2. If a fuse has blown, replace the fuse. Make sure that the new fuse has the correct measurements and rating. For details on the exact locations of the fuse(s) refer to the general drawings, which are part of the project-related documentation. For details on the applicable fuse ratings refer to the power distribution drawings, which are part of the project-related documentation.
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High voltages
Equipment with high voltages (i.e. above 40 Vdc or 30 Vac) are covered by a protective plate or cover. If these voltages are connected, take extra precautions when the protective plates/covers are removed. After checking the voltages, make sure that you put the protective plates/covers back into place.
7.4.4
Checking the AC voltages
AC voltages
All incoming AC voltages connected to the FSC cabinet via fuse terminals or circuit breakers should be within certain levels. To check the AC voltages, take the following steps: 1. Use a multimeter to measure the AC voltage on the incoming side of the fuse terminals. 2. Use a multimeter to measure the AC voltage on the incoming side of the main circuit breaker. If the incoming AC feeders do not meet the requirements laid down in the data sheets of the power supply units (contained in the FSC Hardware Manual), the FSC system and the equipment may be damaged or they may not function properly. For details on the exact locations of the fuse terminals and/or main circuit breakers of the incoming feeders refer to the general drawings, which are part of the project-related documentation. For details on the number of feeders and the voltages required refer to the power distribution drawings, which are part of the project-related documentation.
High voltages
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7.4.5
Checking the correct operation of the PSUs
Operation of PSUs
To ensure correct operation of the FSC system, all AC/DC power supply units located in the FSC cabinet need to be operational and functioning properly. To check the AC/DC power supply units, take the following steps: 1. Check whether the LED which is mounted on each AC/DC power supply unit is on. 2. Check the voltage-monitoring contact of the power supply units. The voltage-monitoring contact of each power supply unit is wired to a digital input module placed in the FSC cabinet or to terminals for external use. (The contacts of the power supply units may be wired in series or individually, depending on the customer requirements.) Under normal conditions, all digital inputs that are wired from the power supply units should be high. If wired to terminals, the contact on these terminals should be closed. (This should be checked on the external device.) For details on the exact locations of the AC/DC power supply units and terminals refer to the general drawings, which are part of the project-related documentation. For details on the wiring of the voltage-monitoring contact of the AC/DC power supply units refer to the power distribution drawings, which are part of the project-related documentation.
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7.4.6
Checking for dust concentration
Dust concentration
The FSC cabinet needs to be checked for dust concentration. As a minimum, the following items need to be checked: Central Part modules, I/O modules, Circuit breakers, and Power supply units. If excessive dust concentrations are found, the equipment needs to be cleaned using an anti-static soft brush. The inside of the FSC cabinet can be cleaned using a vacuum cleaner. Note: To check the dust concentration, the Central Part modules and I/O modules need to be removed from the Central Part and I/O racks. To do this without any risk of personal injury and/or equipment damage, the FSC system needs to be powered down. For detailed information on how to perform a power-down refer to Appendix B of this Service Manual For detailed information on how to perform a power-up refer to Appendix C of this service Manual.
7.4.7
Replacing all dust filters
Dust filters
Every FSC cabinet has one or more filters. They are most commonly mounted in the front and/or rear doors. Before replacing the dust filter, make sure that sufficient new dust filters are available. To replace a dust filter, take the following steps: 1. Remove the cover from the filter. 2. Remove the old dust filter. 3. Place the new dust filter. 4. Place the cover back on the filter. Take the above steps for all filters mounted in the FSC cabinet. For details on the exact locations of filters refer to the general drawings, which are part of the project-related documentation.
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7.4.8
Checking the fasteners on the power distribution rails
Fasteners on power distribution rails
If separate power supply unit cabinets are supplied, it is possible that power distribution rails are present in the FSC cabinet and the power supply unit cabinet. The fasteners used on this power distribution rails need to be checked: 1. Remove the protective plate/cover from the power distribution unit. Warning: Be very careful during the inspection of the fasteners on the power distribution rail as a short circuit may cause a stop of the FSC system. 2. Check whether the fasteners are still properly connected. 3. Place the protective plate/cover back onto the power distribution unit. For details on the exact location of the power distribution rail refer to the general drawings, which are part of the project-related documentation. For details on the tightening torque of the fasteners refer to the data sheets of the manufacturer.
High voltages
7.4.9
Checking all cable clamps
Cable clamps
The cables entering the FSC cabinet are clamped to a cable support/clamp rail, which may be mounted in the FSC cabinet or below a false floor. If the cables are no longer clamped to the cable support/clamp rail, the weight of the cables might put tension on the connections between the cables and the connecting devices, which may result in a loss of signals and eventually a logic trip of the FSC system.
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To check the cable clamps, take the following steps: 1. Visually check whether the cables are still clamped to the cable support/clamp rail. 2. If they are not, tighten the cable clamps or add a new cable clamp. For details on the exact locations of the cable support/clamp rails refer to the general drawings, which are part of the project-related documentation. For details on the tightening torque of the cable clamps refer to the data sheets of the manufacturer.
7.4.10
Checking all shield connections

The shields of the field and system cables that carry signals from certain modules should be connected to the cable support/clamp rail (see Figure 7-5 on the next page). This is in accordance with CE requirements. You should check whether these cables are still properly connected. The above requirement applies to signals from the following module types: 10102/x/x (analog input module) 10214/x/x (loop-monitored digital output module) 10216/x/x (loop-monitored digital output module)
Shielded cables (stripped) Cable clamps
Shield connections
Cable clamp rails
Figure 7-5 Bonding of shielded cables
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7.4.11
Checking all earth/ground connections
Earth/ground connections
Three different earth/ground bars may be available in FSC cabinet: Safety earth/ground, Instrument earth/ground (also called master reference ground, or MRG), and Ex(i) earth/ground. A correct earth/ground connection is required to ensure proper operation of the FSC system.
Safety earth/ground
All mechanical parts of the FSC cabinet are connected to the safety earth/ground bar, which is installed in the FSC cabinet to ensure correct operation. An earth strap is connected from the safety earth/ground bar to the structure of the FSC cabinet. Make sure that the safety earth/ground is still properly connected. The cable of the plant safety earth/ground can be connected to the safety earth/ground bar or a safety earth/ground bolt in the FSC cabinet.
The instrument earth/ground bar is used to connect the shields of field cables and the instrument earth/ground wire of the communication modules. Make sure that the instrument earth/ground is still properly connected. The cable of the plant instrument earth/ground can be connected to the instrument earth/ground bar in the FSC cabinet.
Ex(i) earth/ground
The Ex(i) earth/ground bar is used for the earth connection of Ex(i) equipment. Make sure that the Ex(i) earth/ground is still properly connected. The cable of the plant Ex(i) earth/ground can be connected to the Ex(i) earth/ground bar in the FSC cabinet.
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7.4.12
Testing all hardware I/O
Hardware I/O
All hardware I/O can be checked and tested during the time frame that an FSC system does not control and monitor the process (e.g. during a scheduled process shutdown). Either of two procedures should be used, depending on the system configuration: FSC systems with redundant Central Parts and redundant and/or non-redundant ("single") I/O, or FSC systems with a single Central Part and non-redundant ("single") I/O. Each of these procedures is discussed in more detail below.
Systems with redundant Central Parts
The procedure below discusses how to check and test the hardware I/O for an FSC system with redundant Central Parts. After completion of this procedure, the redundancy for all hardware I/O has been proved. Notes: 1. During this procedure one Central Part will be stopped. Before proceeding with the procedure, use the "Extended Diagnostic" option of the FSC Navigator software to make sure that the other Central Part is fully operational. 2. The procedure below assumes that the FSC system is no longer controlling the process. Contact the operators for verification. To check and test all hardware I/O, take the following steps: 1. Stop Central Part 1 of the FSC system as described in Appendix B of this Service Manual. From this point onward, all hardware I/O will be checked and tested with Central Part 2 operational. 2. Simulate all digital and analog inputs of the FSC system. This can be done on the terminals of the FTAs or terminals mounted in the FSC cabinet or the marshalling cabinet. The status of the digital and analog inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. 3. Simulate all digital and analog outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the FSC Navigator software. Measure all digital and analog outputs
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4. 5.
6.
7.
8.
terminals of the FTAs or terminals mounted in the FSC cabinet or in the marshalling cabinet. Start Central Part 1 as described in Appendix C of this Service Manual. Stop Central Part 2 of the FSC system as described in Appendix B of this Service Manual. From this point onward, all hardware I/O will be checked and tested with Central Part 1 operational. Simulate all digital and analog inputs of the FSC system. This can be done on the terminals of the FTAs or terminals mounted in the FSC cabinet or in the marshalling cabinet. The status of the digital and analog inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. Simulate all digital and analog outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the FSC Navigator software. Measure all digital and analog outputs terminals of the FTAs or terminals mounted in the FSC cabinet or in the marshalling cabinet. Start Central Part 2 as described in Appendix C of this Service Manual.
Systems with a single Central Part
The procedure below discusses how to check and test the hardware I/O for an FSC system with a single Central Part. Note: The procedure below assumes that the FSC system is no longer controlling the process. Contact the operators for verification. To check and test all hardware I/O, take the following steps: 1. Simulate all digital and analog inputs of the FSC system. This can be done on the terminals of the FTAs or terminals mounted in the FSC cabinet or the marshalling cabinet. The status of the digital and analog inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. 2. Simulate all digital and analog outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the FSC Navigator software. Measure all digital and analog outputs terminals of the FTAs or terminals mounted in the FSC cabinet or in the marshalling cabinet.
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7.4.13
Testing all communication links to external devices

All communication links to external devices can be checked and tested during the time frame that an FSC system does not control and monitor the process (e.g. during a scheduled process shutdown). Either of two procedures should be used, depending on the system configuration: FSC systems with redundant Central Parts and redundant and/or non-redundant ("single") I/O, or FSC systems with a single Central Part and non-redundant ("single") I/O. Each of these procedures is discussed in more detail below.
Communication links to external devices
Systems with redundant Central Parts
The procedure below discusses how to check and test the external communication links for an FSC system with redundant Central Parts. After completion of this procedure, the redundancy for all communication links has been proved. Notes: 1. During this procedure one Central Part will be stopped. Before proceeding with the procedure, use the "Extended Diagnostic" option of the FSC Navigator software to make sure that the other Central Part is fully operational. 2. The procedure below assumes that the FSC system is no longer controlling the process. Contact the operators for verification. To check and test all communication links, take the following steps: 1. Stop Central Part 1 of the FSC system as described in Appendix B of this Service Manual. From this point onward, all communication links will be checked and tested with Central Part 2 operational. 2. Simulate all digital and binary inputs of the FSC system. This must be done via the external devices connected to the FSC system. The status of the digital and binary inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. 3. Simulate all digital and binary outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the
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4. 5.
6.
7.
8.
FSC Navigator software, and must be checked via the external devices connected to the FSC system. Start Central Part 1 as described in Appendix C of this Service Manual. Stop Central Part 2 of the FSC system as described in Appendix B of this Service Manual. From this point onward, all communication links will be checked and tested with Central Part 1 operational. Simulate all digital and binary inputs of the FSC system. This must be done via the external devices connected to the FSC system. The status of the digital and binary inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. Simulate all digital and binary outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the FSC Navigator software, and must be checked via the external devices connected to the FSC system. Start Central Part 2 as described in Appendix C of this Service Manual.
Systems with a single Central Part
The procedure below discusses how to check and test the communication links for an FSC system with a single Central Part. Note: The procedure below assumes that the FSC system is no longer controlling the process. Contact the operators for verification. To check and test all communication links, take the following steps: 1. Simulate all digital and binary inputs of the FSC system. This must be done via the external devices connected to the FSC system. The status of the digital and binary inputs can be checked using the "FSC On-Line Environment" option of the FSC Navigator software. 2. Simulate all digital and binary outputs of the FSC system. This can be done using the "FSC On-Line Environment" option of the FSC Navigator software, and must be checked via the external devices connected to the FSC system.
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Section 8 Troubleshooting and Fault-Finding

This section describes the troubleshooting and fault-finding in connection with the FSC system. It covers the following topics:
See page
Section overview
Subsection 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.4
Topic
Section overview........................................................................................... 121 Notification of alarms and errors................................................................... 122 Retrieving diagnostic information from the FSC system .............................. 123 Visible and/or audible alarms ....................................................................... 123 FSC Navigator software................................................................................ 123 Diagnostic and Battery Module (DBM) ......................................................... 125 Sequence-of-Event (SOE) station ................................................................ 125 Acting on the information retrieved............................................................... 127
Important! An alarm/error message generated by the FSC system requires immediate attention and action. Ignoring an FSC alarm/error message may cause severe damage to the equipment and/or serious injury to people.
Service Manual Section 8: Troubleshooting and Fault-Finding
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8.2
Notification of alarms and errors

There are a number of ways in which the user can be informed of an alarm/error detected by the FSC system. This can be done via: Visible alarms on the DCS system, Audible alarms, the FSC Navigator software (running on an FSC user station connected to the FSC system), a Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) placed in the Central Part(s), Sequence-of-Events (SOE) recording devices, and External devices. Depending on customer requirements, one or more of the above options may be actually used. Each of these options is discussed in more detail in the subsection 8.3. Notes: 1. Alarm/error messages are stored in a buffer in the FSC system. If the buffer is full, the oldest information will be overwritten. 2. The only correct way of retrieving extended diagnostic information from the FSC system is by using the "Extended Diagnostics" option of the FSC Navigator software. If you choose this option, the information is also automatically stored on the hard disk of the FSC user station for future reference. For details refer to Section 12 of the FSC Software Manual. 3. Always retrieve extended diagnostics prior to activating the FSC reset key switch. If this key switch is activated, the buffer in the FSC system is cleared and all alarm/error information is lost.
Notification of alarms and errors
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8.3
Retrieving diagnostic information from the FSC system

As described in the previous subsection, the user can be notified of alarms and errors in a number of different ways. The diagnostic information that accompanies these alarms and errors can also be retrieved in different ways. Each of these is discussed in the following subsections.
Retrieving diagnostic information
8.3.1
Visible and/or audible alarms
Visible and/or audible alarm
Functional Logic Diagrams (FLDs) can be designed which will activate a digital output if an alarm/error is detected in the FSC system. This digital output will subsequently trigger a visible and/or audible signal. After acknowledging this visible and/or audible alarm, the operator will have to investigate the cause of the alarm. This can be done in different ways as described below in the next few subsections.
8.3.2
FSC Navigator software
Using an FSC user station
The FSC Navigator software (running on an FSC user station connected to the FSC system) allows you to retrieve the most detailed information on the status of the FSC system. This information can be retrieved using the "Extended Diagnostics" option of FSC Navigator. If you choose this option, FSC Navigator retrieves all diagnostic messages from the current application and displays them on screen (see Figure 8-1 on the next page). All diagnostic data that is retrieved from the FSC system is stored in a database file on your hard disk. The following information is displayed on screen: module name, short description of the event, rack and position of hardware modules, and time and date of event.
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Figure 8-1 Viewing the extended diagnostic information The retrieved diagnostic information is presented in ascending chronological order, i.e. the most recent event is shown on the last line. All diagnostic information that is retrieved from the application is stored in the extended diagnostics database. If the FSC system has a redundant configuration, FSC Navigator retrieves and stores the diagnostic information from all Central Parts. The diagnostic information of the application's selected Central Part is displayed. You can switch between Central Parts by pressing Alt + <C>. If the list of diagnostic messages does not fit on one screen, you can use the up and down arrow keys ( and ) or <PgUp> and <PgDn> to browse through the list. For further details on the information retrieved by the FSC Navigator software refer to Section 12 of the FSC Software Manual.
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8.3.3
Diagnostic and Battery Module (DBM)

The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part rack(s) continuously provide status information of the FSC system. In default mode, the current time is shown. Diagnostic information, if available, can be retrieved by (repeatedly) pushing the switch on the DBM module downward. For details on how to interpret the diagnostic information displayed refer to the DBM module data sheets in the FSC Hardware Manual. Notes: 1. The information provided by the DBM modules is fairly limited. If you want more extensive information, you should use the FSC Navigator software to interface with the FSC system (see subsection 8.3.2). 2. Before replacing modules or activating the reset key switch of the FSC system, always retrieve detailed diagnostic information by using the FSC Navigator.
Using the DBM
8.3.4
Sequence-of-Event (SOE) station

If a sequence-of-event recording (SER) device has been configured in the FSC application, each individual I/O signal can be set to "SER-enabled". This means that if the SER-enabled tag number changes state, the information from that particular tag number is sent to an SOE station with the HSMS proprietary FSCSOE software running on it. This is a Windows-based application which retrieves events from the FSC system and stores them in a database. The user can view the events on-line (i.e. while being retrieved from the connected FSC systems) or from disk (e.g. for post-mortem analysis). The following events can be recorded by FSCSOE: FSC events of process variables of types I, O, AI, AO (process variable events) FSC force events of variable of types I, O, AI and AO (force events) FSC variable value reports of variables of type BO (report events) FSC system events: FSC system fault (diagnostic events) loop-monitoring fault events (diagnostic events) SOE buffer full events.
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Using an SOE station
If no SOE station is connected to the FSC system, the SER information is stored in a buffer, which can hold at least 448 events. If the SER buffer is full, the oldest SER information is overwritten. Notes: 1. The information on the SOE station is mainly for recording the history of the FSC system. Please note that this is general information. If, for example, a communication error is detected, no information is provided as to which communication interface is affected. If you want more extensive information, you should use the FSC Navigator software to interface with the FSC system (see subsection 8.3.2). 2. Before replacing modules or activating the reset key switch of the FSC system, always retrieve detailed diagnostic information by using the FSC Navigator.
External devices
It is also possible to communication with external devices, for example: RS-232 Modbus communication to an EPLC gateway, or Using the FSC-SMM for communication with the UCN.
RS-232 Modbus communication
If RS-232 Modbus communication is used, additional FLDs need to be designed which will ensure that the external device is informed of the alarm/error messages generated. The FSC system can be integrated into the TPS system using the FSC Safety Manager Module (FSC-SMM). If that is the case, the FSC diagnostics are also available at the TPS operator stations (US, UXS, GUS).
FSC-SMM communication
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8.4
Acting on the information retrieved

Action needs to be taken based on the information retrieved from the FSC system. The following procedure should be followed: 1. Examine the diagnostic information retrieved from the FSC system. This information will provide details on why the alarm/error message was generated by the FSC system and whether action has already been taken by the FSC system. For detailed information on the alarm/error messages retrieved from the FSC system refer to Section 12 of the FSC Software Manual. 2. Solve the cause of the alarm/error message. The extended diagnostics will help you identify the cause of the alarm/error and define a solution. Possible solutions may be: Replacing a field device, Replacing faulty equipment (see the FSC Maintenance & Replacement Guide, doc. ref.: FS99-505), or Modifying the FSC application (see Section 9 of this Service Manual). 3. Make sure that after the cause of the alarm/error has been solved, the FSC system is fully operational again. Important! An alarm/error message generated by the FSC system requires immediate attention and action. Ignoring an FSC alarm/error message may cause severe damage to the equipment and/or serious injury to people.
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Section 9 Service and/or Modification to the FSC Cabinet

This section provides information on the servicing and modifications that can be performed on the FSC cabinets. It covers the following topics:
See page
Section overview
Subsection 9.1 9.2 9.2.1 9.2.2 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.4.7 9.4.8 9.4.9 9.4.10 9.4.11 9.4.12
Topic
Section overview........................................................................................... 129 Service and modification overview ............................................................... 130 Important considerations .............................................................................. 130 On-line modification ...................................................................................... 131 Hardware service and/or modification to the FSC cabinet ........................... 132 Introduction ................................................................................................... 132 Adding a communication module ................................................................. 132 Adding an I/O rack ........................................................................................ 133 Adding I/O modules ...................................................................................... 133 Adding wiring to existing circuit breaker ....................................................... 134 Changing converter modules........................................................................ 135 Calibrating transmitters................................................................................. 138 Key coding .................................................................................................... 138 Updating documentation............................................................................... 139 Software service and/or modification to the FSC cabinet............................. 140 Introduction ................................................................................................... 140 Verifying the application files ........................................................................ 140 Backing up the application files .................................................................... 141 Adding/changing FLDs ................................................................................. 142 Renumbering FLDs....................................................................................... 143 Adding/changing timers ................................................................................ 143 Changing counters........................................................................................ 143 Loopback of sheet references ...................................................................... 144 EPROM/RAM size ........................................................................................ 146 Square root of a negative value.................................................................... 146 Divide by zero ............................................................................................... 146 Range-checking errors ................................................................................. 147
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9.2
Service and modification overview
9.2.1
Important considerations
Important! 1. The amount of human interaction during service and/or modification to the FSC system may be considerable. These actions should therefore be carried out with the utmost care, and by authorized and qualified persons only. In case of problems during the service or modification work, the FSC system can go to a safe state resulting in a process shutdown. 2. Before any service or modification work is done on the FSC system, make sure that all permits have been obtained from the plant operator.
It is recommended that a Honeywell SMS representative is present to perform an on-line modification. This is to ensure that the correct procedures are being followed. Moreover, should any problems arise during the modification, they can be solved on the spot. For restrictions and need-to-know items for hardware-related service and/or modifications refer to subsections 9.3. For restrictions and need-to-know items for software-related service and/or modifications refer to subsection 9.4.
Restrictions and need-to-know items
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Section 9: Service and/or Modification to the FSC Cabinet
9.2.2
On-line modification
On-line modification (OLM) is a TV-approved FSC system option which allows you to modify the application software, system software and the FSC hardware configuration of redundant systems, while the system remains operational. During on-line modification, the changes are upgraded in one Central Part at a time. Meanwhile, the other Central Part continues to monitor the process. An on-line modification can only be performed on an FSC system with redundant Central Parts and with the on-line modification parameter of the application activated (i.e. set to "Yes" in the FSC configuration database). Note: For more detailed information on on-line modifications to the FSC system refer to Appendix D of the FSC Software Manual ("On-Line Modification").
Risks
Considerable human interference may be required during on-line service and/or modification to the FSC system. This will greatly increase the risk of an error which may result in an alarm generated or error detected by the FSC system and/or a stop of one or more Central Parts in the FSC system. This, in turn, may result in a total plant trip. It is therefore strongly recommended to only perform service and/or modification work if it is really required and if the process in the plant allows it. Updating service or qualification descriptions of tag numbers or adding text on FLD pages are generally not worth the risk of a plant trip during on-line modification. Notes: 1. During an on-line modification, one Central Part will be stopped. Use the Extended Diagnostics option of the FSC Navigator software to verify that both Central Parts are fully operational before starting the on-line modification. 2. During the time that one of the Central Parts of an FSC system with redundant Central Parts is stopped, the FSC system is not running with increased or high availability. 3. The FSC cabinet may have two Central Parts that do not contain identical communication interfaces. It will then be possible to perform an on-line modification, but information to/from external communication devices may be lost.
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9.3
Hardware service and/or modification to the FSC cabinet
9.3.1
Introduction
General
This section discusses hardware-related service and/or modification to the FSC cabinet. It covers the restrictions and need-to-know information for the following items: Adding a communication module (see subsection 9.3.2), Adding an I/O rack (see subsection 9.3.3), Adding I/O modules (see subsection 9.3.4), Adding wiring from an existing circuit breaker (see subsection 9.3.5), Changing converter modules (see subsection 9.3.6), Calibrating transmitters (see subsection 9.3.7), Key coding (see subsection 9.3.8), Updating documentation (see subsection 9.3.9).
9.3.2
Adding a communication module
Adding a communication module
The communication modules are placed in the Central Part of the FSC system. A system bus is mounted at the rear of the Central Part. The following items need to be taken into consideration when adding a communication module: Verify that the installed DC/DC converter (HSMS type 10300/1/1) has sufficient spare capacity to supply power to the additional communication module (see the power consumption calculation). A jumper on the rear of the system bus will need to be removed. Check the jumper setting on the new communication module to be installed. For detailed information on the jumper settings refer to the FSC Hardware Manual.
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9.3.3
Adding an I/O rack
Adding an I/O rack
An I/O rack cannot be added on line. It can only be added if the FSC system has been powered down. This is because the vertical bus flatcables, the flatcables to the horizontal buses and/or the Horizontal Bus Drivers (HBDs) will need to be modified.
9.3.4
Adding I/O modules
Adding I/O modules
The procedure below discusses the actions to be taken when adding I/O modules to an operational FSC system. It will help prevent that an FSC system will stop due to an error found on a newly installed I/O module at the moment the new application is loaded into the FSC system. There is no difference between adding I/O modules in a nonredundant ("single") I/O section or a redundant I/O section. Take the following steps when adding new I/O modules to an operational FSC system: 1. Add the hardware in the FSC system. 2. Update the application of the FSC system. Make sure that the safety relation of the new I/O modules is set to "No". 3. Load the new application into the FSC system. 4. Check and test all I/O wired to and from the new I/O modules for open loop, short circuit and high voltages. 5. After verification of the items mentioned in the previous step, update the FSC application and set the safety relation of the I/O modules and I/O signals to "Yes" (if required). 6. Load the new application into the FSC system.
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9.3.5
Adding wiring to existing circuit breaker
If the new I/O modules are assigned to an existing group, you may Adding wiring to an existing circuit need to add the external I/O wiring to an existing circuit breaker. Normally the wiring on the secondary side of the circuit breaker is breaker looped from the circuit breaker, via all pins on the rear of the I/O backplanes (HSMS type 1031x/x/x), and reconnected to the secondary side of the circuit breaker. The recommended modification procedure depends on the status of the FSC system: All Central Part(s) stopped, Powered down, or Fully operational. Note: Any mistake during this modification may result in a stop of the Central Part(s) of the FSC system. It is therefore recommended that any wiring modifications are carried out with the FSC system fully powered down (if possible).
All Central parts stopped
When all Central Parts of an FSC system are stopped, power down the FSC system to avoid any damage to the electronic equipment and/or injury to people during the modification. If the FSC system is powered down, the loop from the secondary side of the circuit breaker can be disconnected from the rear of the I/O backplane. You can then carry out all modification required to connect power to the new I/O modules. If the FSC system is fully operational and cannot be stopped, it is recommended that you add a new circuit breaker for the new I/O modules. In this way no modifications to existing wiring need to be made.
FSC system powered down
FSC system fully operational
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9.3.6
Changing converter modules
Changing converter modules
Converter modules are placed at the rear of the backplane, and they are used to set the ranges for the analog input and output module and the sense for the digital output module. Converter modules (identified by 10xxx/A/x) are available for the following I/O modules: 10102/2/1 (4-channel analog input module), 10105/2/1 (16-channel analog input module), 10106/2/1 (16-channel digital input module), 10205/2/1 (2-channel analog output module), and 10216/2/x (4-channel digital output module with line-monitoring). For technical specifications of these converter modules refer to the FSC Hardware Manual. Removal of converter modules from the backplane is detected by the FSC system. The next few pages discuss the system response for the various I/O module types. Note: The converter modules for unallocated channels can be changed without any problems. The on-line features of FSC Navigator allow you to check the channels before allocating a tag number.
10102/2/1 analog input module
If a converter module of a 10102/2/1 analog input channel is removed, the analog input signal is lost. This behavior is identical for FSC systems with redundant and/or non-redundant ("single") analog input modules. If the converter module is removed, the Central Part(s) will report the loop status of the analog input signal as being faulty. The loop status diagnostic input SensAI will go to '0' (zero). The only way to prevent losing the analog input value and the SensAI diagnostic input is forcing the analog input channel before removing the converter module. After the converter module has been exchanged, a system reset is required (by cycling the WD Reset key switch).
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10105/2/1 analog input module
If the converter module of a 10105/2/1 analog input module is removed, the 16 analog input signals allocated to this module are lost. This behavior is identical for FSC systems with redundant and/or non-redundant ("single") analog input modules. If the converter module is removed, the Central Part(s) will report the loop status of the analog input signal as being faulty. The loop status diagnostic input SensAI will go to '0' (zero). The only way to prevent losing the analog input value and the SensAI diagnostic input is forcing the analog input channel before removing the converter module. After the converter module has been exchanged, a system reset is required (by cycling the WD Reset key switch).
10106/2/1 digital input module
If the converter module is removed, the state of the digital input signal depends on the device connected. The only way to prevent problems is forcing the digital input signals. After the converter module has been exchanged, a system reset is required (by cycling the WD Reset key switch). The 10205/2/1 analog output module is a fail-safe module, which means that it has diagnostic capabilities. In case of a fault, the I/O module is able to detect the fault and respond to it. The action taken depends on the safety relation of the I/O signals allocated to this module. If the converter module is removed, the output signal in the field is lost and the output channel is reported faulty by the FSC system. After the converter module has been exchanged, a system reset is required (by cycling the WD Reset key switch). If the converter module is removed, the output signal in the field is lost and the output channel is reported faulty by the FSC system. As the output channel has been defined as safety-related, the total FSC system will stop. The only way to avoid this is to perform an on-line modification during which the safety relation of the analog output channels allocated to the 10205/2/1 module is set to "No". The converter module can then be replaced without stopping the FSC system. After a system reset (using the WD Reset key switch) and verification that everything is in order, a second on-line modification needs to be performed to set the outputs allocated to the 10205/2/1 module back to their original safety relation setting.
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I/O signals not safety related
I/O signals safety related
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Important! As an error on an analog output will result in a total stop of the FSC system, it is strongly recommended that the safety relation of analog output modules is always set to "No".
Note: For details on on-line modifications refer to Appendix D of the FSC Software Manual.
10216/2/x digital output module
The 10216/2/x digital output module is a fail-safe module, which means that it has diagnostic capabilities. In case of a fault, the I/O module is able to detect the fault and respond to it. The action taken depends on the safety relation of the I/O signals allocated to this module. If the converter module is removed, the output signal in the field is lost and the output channel is reported faulty by the FSC system. After the converter module has been exchanged, a system reset is required (by cycling the WD Reset key switch). If the converter module is removed, the output signal in the field is lost and the output channel is reported faulty by the FSC system. As the output channel has been defined as safety-related, the total FSC system will stop. The only way to avoid this is to perform an on-line modification during which the safety relation of the digital output channels allocated to the 10216/2/x module is set to "No". The converter module can then be replaced without stopping the FSC system. After a system reset (using the WD Reset key switch) and verification that everything is in order, a second on-line modification needs to be performed to set the outputs allocated to the 10216/2/x module back to their original safety relation setting. Note: For details on on-line modifications refer to Appendix D of the FSC Software Manual.
I/O signals not safety related
I/O signals safety related
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9.3.7
Calibrating transmitters
During the calibration stage of a transmitter, it is recommended that you force the analog input whose transmitter is being calibrated. When transmitters are calibrated, signals are superimposed on the normal analog input signal. This will cause fluctuations in the analog input signals, which will be detected by the FSC system. These fluctuation are handled as normal changes in the analog input signal, which might cause the safety application to respond. For FSC system with analog input modules placed in a redundant I/O rack, an input compare error will be generated if the analog input value of Central Part 1 and Central Part 2 differ by more than 2% of the full scale for the duration of the configured process safety time.
Calibrating transmitters
9.3.8
Key coding
The locations of the I/O modules in the I/O rack(s) are not predetermined by FSC Navigator, but they are user-defined via the System Configuration option. To ensure proper interfacing with the field devices (wiring, etc.) and to prevent damage to equipment, the I/O modules must be placed at the I/O rack positions as defined in FSC Navigator. To prevent insertion of an incorrect module type on a certain I/O position, the I/O rack connector and the module connector are keycoded with coding pins. If you add I/O modules, make sure that the correct key coding is also added. Notes: 1. Incorrect placement of I/O modules in the backplane, due to incorrect and/or missing key coding, may result in a total stop of the FSC system involved. It is therefore essential that the backplanes are coded correctly. 2. FSC Central Part modules do not require key-coding. For detailed information on the key coding for the I/O modules refer to the FSC Hardware Manual.
Key coding
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9.3.9
Updating documentation
If any hardware servicing and/or modifications are performed on the FSC cabinet, make sure that the master documentation set is updated accordingly. Note: If you do not update the documentation, you may encounter problems during maintenance, service and/or modification in the future.
Update documentation
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9.4
Software service and/or modification to the FSC cabinet
9.4.1
Introduction
General
This section discusses software-related service and/or modification to the FSC cabinet. It covers the restrictions and need-to-know information for the following items: Verifying the application files (see subsection 9.4.2), Backing up of application files (see subsection 9.4.3), Adding/changing FLDs (see subsection 9.4.4), Renumbering FLDs (see subsection 9.4.5), Adding/changing timers (see subsection 9.4.6), Changing counters (see subsection 9.4.7), Loopback of sheet references (see subsection 9.4.8), EPROM/RAM size (see subsection 9.4.9), Square root of a negative value (see subsection 9.4.10), Divide by zero (see subsection 9.4.11), and Range-checking errors (see subsection 9.4.12).
9.4.2
Verifying the application files
Verifying application files
Before starting any modification to the FSC application, you need to make sure the application in the FSC system is identical to the application that is stored on the FSC user station. This can be done in either of the following two ways: 1. Verification of the application, or 2. Accessing 'live' FLDs. Note: Both methods require a connection to your FSC system via an FSC Development System (FSC-DS) communication link.
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Application verification
To verify the application in the FSC system against the application on the FSC user station, choose the 'Verify Application' option of FSC Navigator. For details refer to Section 11 ("Verifying an Application") of the FSC Software Manual. A log file is generated which provides the required information. Note: The Verify Application option is not available with the Demo and Contractor versions of the FSC Navigator software.
Accessing 'live' FLDs
An alternative verification method is by accessing 'live' FLDs. To access 'live' FLDs, do the following: 1. In FSC Navigator, go to the On-Line Environment screen. 2. Click on the Process Status Monitoring button. 3. From the drop-down menu, choose the Monitor FLDs option. 4. You are now prompted to specify an FLD. Enter the FLD number or press <?> to choose from a list of available FLDs. If FSC Navigator can access the selected FLD, the correct version of the FSC application files is stored on the FSC user station. Important! If the incorrect versions of FSC application files are used, an on-line modification to the FSC system cannot be completed without a total stop of the FSC system.
9.4.3
Backing up the application files
Backing up the application files
After verification that the correct FSC application files are used, you should always make a backup of the application files before carrying out any modifications. You should also make a backup after the modifications to the FSC system have been completed successfully. Make a backup of all files in the applicable project directory. The project directory is always a subdirectory of the FSC application directory (C:\FSC by default). The name of the directory is identical to the project name. Thus, if you have a project called 'PROJ', the corresponding project files will be located in a subdirectory called
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'PROJ' (usually C:\FSC\PROJ\). Make sure that you remember the directory name, and that you copy all files in the project directory. Important! Make sure that Windows 95/98 shows all files, and does not hide certain system files. Otherwise any FLDs with the number 386 will not be backed up, which means your project can no longer be translated successfully (because of a missing FLD). To make sure all files are shown, do the following: 1. Start Windows Explorer. 2. From the View menu, choose the Options item. 3. Make sure the 'Show all files' option button is selected. 4. Choose the OK button to confirm the change. The changes will take effect immediately. You do not need to reboot your computer.
9.4.4
Adding/changing FLDs
Adding/changing FLDs
It is possible to delete, add and/or change FLDs during an on-line modification. However, always make sure to check the impact of any deletions, additions or changes to FLDs before carrying out the actual on-line modification. After the FSC system is restarted, all FLDs (including the ones that were changed) are executed in accordance with the status of the input signals. This means, for example, that output signals may be affected by the initial state of the related input signals, which may have a serious impact on the safety application. If, for example, a new digital input signal is added to an existing AND gate and this signal is not yet connected to a field device, its initial value at system start-up will be '0' (zero). This means that the output signal of the AND gate will be lost (i.e. set to '0') if the FSC system is (re)started. Depending on the safety application, this might have an impact on the process.
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9.4.5
Renumbering FLDs
FLDs cannot be renumbered in the FLD design editor if the on-line modification option has been activated (i.e. set to "Yes"). The 'Renumber' option will then not be available in the editor menus. You might be tempted to temporarily set the on-line modification option to "No", renumber the FLDs, and then change the on-line modification option back to "Yes". The FLD numbering will then indeed be updated. However, if you do this, the modified application cannot be loaded into the FSC system on-line (i.e. through an on-line modification). Instead, this should be done off-line. Any subsequent modifications can be performed on-line again (providing the on-line modification option is not set to "No" again.)
Renumber FLDs
9.4.6
Adding/changing timers
Changing a timer value may cause the timer output to pulse for the duration of one cycle time. If you change a time value, make sure that the pulse of the timer output does not have an impact on the process controlled by the FSC system. The input of variable timers may not go below 0 or exceed 2047. When adding timers during an on-line modification, always make sure that the input to the timer will never exceed the above values. If the timer input value does exceed the above values, the FSC system will automatically stop.
Changing a timer
Adding a timer
9.4.7
Changing counters
The maximum counter value is defined in the FLDs (between 0 and 8191). During normal operation of the FSC system, the counter input value can be changed by activating the set input. When changing the maximum value of the counter, always make sure that the input value of the counter is not higher than the maximum value. Otherwise the FSC system will stop automatically.
Changing counters
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9.4.8
Loopback of sheet references
Loopback of sheet references
A loopback is an off-sheet reference to a destination FLD with a lower number than the source FLD. Even though the FSC Navigator software allows this, you should be cautious about using them. Loopbacks have certain consequences for value processing, which may be wanted behavior, but might also be design errors. Note: FSC Navigator R510 and higher offer the Safety Checker option, which reports all loopback off-sheet references.
Output
Input
FLD 100
FLD 110
(A) Off-sheet reference to FLD with higher number
Input
Output
FLD 100
FLD 110
(B) Off-sheet reference to FLD with lower number
Figure 9-1 Off-sheet references and loopbacks

Off-sheet reference to FLD with higher number
Situation (A) in Figure 9-1 above shows a "normal" off-sheet reference. It refers to an FLD with a higher number. The FSC system scans all hardware inputs once per application cycle, after which the FLDs are executed sequentially, starting with the FLD with the lowest number.
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This means that any operation on the reference target (the input on FLD 110 in Figure 9-1) is done using the latest value of the reference source (the output on FLD 100). No time is "wasted".
Off-sheet reference to FLD with lower number
Situation (B) in Figure 9-1 above shows an off-sheet reference that refers to an FLD with a lower number. Since the FSC system scans all hardware inputs only once per application cycle, this means that for one application cycle an operation on the reference target (the input on FLD 100 in Figure 9-1) is done using an "old" value of the reference source (the output on FLD 110). After all, the input value of the operation is not determined until later. It takes one application cycle for the reference target to be updated. If there are nested loopbacks (i.e. a loopback in a loopback), the time delay will increase by one application cycle for every nested loopback. This time delay will usually not be wanted behavior, but design errors which may violate the intended functionality of the application. Loopbacks should therefore always be looked at very critically. If loopbacks cannot be avoided, it should be investigated which signals can be looped back without violating the intended functionality of the application. For example, a loopback for MOS/OOS/bypass signals is no cause for alarm.
It is possible to add loopbacks in an existing FSC system during an on-line modification. Please note that the power-up status for a new off-sheet reference is set to "Off" by default. This means that if the loopback is added, the off-sheet reference and on-sheet reference will be low for at least one cycle. Depending on the FLDs, this might result in a shutdown of one or more units, or even a total plant shutdown. Adding loopbacks during an on-line modification of an existing operational FSC system should therefore always be looked at very critically.
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9.4.9
EPROM/RAM size
EPROM/RAM size
The information in this section does not apply to FSC system which contain Central Part modules with flash memory. After the modification to the FSC application have been made and the "Translate Application" option of FSC Navigator has been completed successfully, check the translation log file. This log file will show the size of the required EPROMs or RAM chips. Next, check the size of the EPROMs or RAM chips contained in the FSC system. If the sizes do not match, new EPROMs or RAM chips are required, and jumper setting on the Central Part modules will need to be changed. For detailed information on the jumper setting of the Central Part modules refer to the FSC Hardware Manual.
9.4.10
Square root of a negative value
Square root of a negative value
The square-root function of a negative value cannot be executed. When adding a square-root function during an on-line modification, always make sure that the input value of the square-root function can never be a negative number. If the square-root function is performed on a negative number, the FSC system will stop automatically.
9.4.11
Divide by zero
Divide by 0
A divide-by-zero operation cannot be executed. When adding a division function during an on-line modification, always make sure that the denominator can never be zero. If the denominator becomes zero, the FSC system will stop automatically.
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9.4.12
Range-checking errors
Range-checking errors
The values used in the FSC system may not exceed their minimum and maximum values. If these minimum or maximum values are exceeded after a mathematical operation (subtraction, addition, multiplication, division or conversion), the FSC system will stop automatically. To avoid this situation, additional logic may need to be designed. Only downward conversions are allowed (see Table 9-1). Table 9-1 Conversion table
Source ('From') B W L F B Yes Yes Yes Target ('To') W No Yes Yes L No No Yes F No No No
S = Source signal type (before conversion) T = Target signal type (after conversion) B = Byte (8 bits) W = Word (16 bits) L = Long (32 bits) F = Floating point (32 bits) Table 9-2 below shows the minimum and maximum values of the various register types. Table 9-2 FSC register types
Register type Byte (8-bit) Word (16-bit) Long (32-bit) Float (32-bit) Integer/Real Integer Integer Integer Real Minimum value 128 32,768 2,147,483,648 10e38 Maximum value +127 +32,767 +2,147,483,647 +10e38
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Section 10 Training Courses

Section overview This section provides general information on the courses available with respect to the FSC system. It covers the following topics:
See page
Subsection 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10
Topic
Section overview........................................................................................... 149 Training overview.......................................................................................... 150 Fail Safe Controller Managers Overview course (4501) .............................. 151 Introduction to IEC 61508 course (4504)...................................................... 152 Fail Safe Controller Implementation course (4508) ...................................... 153 Fail Safe Controller Maintenance course (4505) .......................................... 154 Fail Safe Controller On-Line Modification course (4502) ............................. 155 Fail Safe Controller Advanced course (4512)............................................... 156 Fail Safe Controller Total Package course ................................................... 157 Customized training courses ........................................................................ 157
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10.2
Training overview
Various training programs are available which enable users to become familiar with the FSC system. The training courses can be given at Honeywell locations, but they can also be organized on site, if required. The available training courses are listed below. In addition to a number of standard programs, there is also the option of having training courses tailored to the customer's specific needs. This allows extra options to be added to the training, or it can be used to focus on specific segments.
Overview
Whom to contact for For further details please contact your local Honeywell affiliate or Honeywell SMS Regional Delivery Center (RDC). training courses Available courses The following FSC-related training courses are available: Fail Safe Controller (FSC) Managers Overview (course number 4501) (see subsection 10.3), Introduction to IEC 61508 (course number 4504) (see subsection 10.4), Fail Safe Controller (FSC) Implementation (course number: 4508) (see subsection 10.5), Fail Safe Controller (FSC) Maintenance (course number: 4505) (see subsection 10.6), Fail Safe Controller (FSC) On-Line Modification (course number: 4502) (see subsection 10.7), Fail Safe Controller (FSC) Advanced (course number: 4512) (see subsection 10.8), Fail Safe Controller (FSC) Total Package (see subsection 10.9), and Customized training courses (see subsection 10.10). Each of these courses is discussed in more detail in the next few subsections.
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10.3
Fail Safe Controller Managers Overview course (4501)

This one-day course provides an overview of all basic features and functions of the FSC system. The course is intended for both technical and non-technical managers in areas including operations, engineering, production, maintenance, purchasing, finance, and human resources. Students will learn what the FSC system is, what it can do, what information it can provide, and what is involved in implementing, operating, and maintaining it. None. The following topics are addressed: Overall FSC philosophy, FSC configuration and structure, FSC hardware, Designing functional logic diagrams (FLDs), What the Operator can do, What the Engineer can do, What Maintenance can do, How to work with sequence of events, and The integration with TPS100.
Overview
Prerequisites Contents
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10.4
Introduction to IEC 61508 course (4504)

This one-day safety seminar provides an introduction to the new international safety standard IEC 61508, and helps you answer a number of important safety questions (see below). The following prerequisites are required: Knowledge of process control.
Overview
Prerequisites
Contents
Many companies are currently working to implement the emerging international safety standard IEC 61508. The HSMS Safety Consultancy group helps engineering contractors, system integrators and end-users in the process industry adopt this standard and implement its requirements in a structured manner. This one-day safety seminar provides an introduction to the new international safety standard IEC 61508, and helps you answer the following important safety questions: 1. What are the potential hazardous events and their associated risks, and what risk reduction is required to achieve an acceptably safe process installation? 2. How can it be established and confirmed that the chosen safeguarding measures/equipment realize the required risk reduction (e.g. realize a specific SIL level)? 3. What activities need to be carried out to guarantee that this SIL level is maintained during the entire lifetime of the safeguarded process installation?
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10.5
Fail Safe Controller Implementation course (4508)

This four-day course provides the training for engineering personnel in the implementation of FSC projects. It covers the technical aspects of the system, including safety and availability considerations. Programming of the system is included, as well as the communication with the Safety Manager Module (TPS100). The following prerequisites are required: Knowledge of process control, instrumentation, and a general electrical background. Logic and configuration experience. Background experience in primary and final control elements and their function is helpful, along with any previous PLC implementation, configuration, and installation and maintenance experience. If the FSC is used in a TPS environment, knowledge of the LCN and UCN status and detail displays is required. Working knowledge of PC Windows interface (logging on, desktop operation, navigation, starting programs, file operations).
Overview
Prerequisites
Contents
The following topics are addressed: Overall FSC philosophy, FSC configuration and structure, FSC hardware, Design of the functional logic diagram, Programming and installing EPROMs in the FSC system, FSC on-line package, FSC database and database packages, FSC programming, Programming the FSC and SMM (TPS100) to enable data exchanges, and TPS100 (SMM) diagnostics.
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10.6
Fail Safe Controller Maintenance course (4505)

This four-day course provides the training for maintenance personnel to enable them to support the FSC system with first-call maintenance. The following prerequisites are required: Knowledge of process control, instrumentation, and a general electrical background. Background experience in primary and final control elements and their function is helpful, along with any previous PLC implementation, configuration, and installation and maintenance experience. If the FSC is used in a TPS environment, knowledge of the LCN and UCN status and detail displays is required. Working knowledge of PC Windows interface (logging on, desktop operation, navigation, starting programs, file operations).
Overview
Prerequisites
Contents
The following topics are addressed: Overall FSC philosophy, FSC configuration and structure, FSC hardware, Working with functional logic diagrams, Programming and installing the FSC system, Working with the FSC on-line package: EPROM programming, Diagnostics, Loading applications/on-line modifications, Working with the FSC and Safety Manager Module (SMM) data exchanges, and TPS100 (SMM) diagnostics.
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10.7
Fail Safe Controller On-Line Modification course (4502)

This two-day On-Line Modification (OLM) course is required for those how want to make changes to a running system ('on-line'). Training is essential here, because on-line modification can have a major impact on the process. If not done properly, OLM may lead to a total plant shutdown. All the exercises will be done using running FSC systems. The OLM course can only be given at the HSMS Center of Excellence in 's-Hertogenbosch, the Netherlands (NL33). Participants to the OLM course must already have completed the FSC Implementation course (4508). The following topics are addressed: Brief review of FSC configuration and structure, On-line modification of the application, On-line modification of the system software, On-line modification in conjunction with TPS100, On-line modification of hardware modules, Do's and don'ts regarding on-line modification, and Fault-finding before and during on-line modification.
Overview
Prerequisites
Contents
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10.8
Fail Safe Controller Advanced course (4512)

This five-day course covers the FSC system basics programming, the operation, troubleshooting techniques, diagnostics and on-line changes. Students perform systematic troubleshooting. Approximately 50% of course time is devoted to hands-on laboratory exercises. The latest system hardware will be used in conjunction with the latest software features, such as flash memory operation ("full download") and the PlantScape integration. The Implementation course (4508) and experience with FSC systems in general. The following topics are addressed: Fault-finding before and during on-line modification, Introduction of the latest FSC release, Working with FSC and PlantScape, Working with FSC and TDC / TPS, Working with flash memory ("full download option"), Explanation and demonstration of potential faults, Fault-finding methods, On-line modifications on FSC systems: Upgrade from old releases to the latest release, Application changes, Together with TDC, Together with PlantScape, Communication aspects, and Questionnaire of overall FSC philosophy.
Overview
Prerequisites
Contents
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10.9
Fail Safe Controller Total Package course

This five-day course combines the FSC Implementation course (4508) and the FSC On-Line Modification course (4502). It is required for those who want to perform modifications in the field, or who are responsible for controlling and modifying running systems.
Overview
10.10 Customized training courses

Overview Customized training courses are also available which are specifically geared to the customer's specific needs. These courses will always be set up in cooperation with the customer, for example to focus on any discipline required for a particular site. Upon customer demand, special training courses are available that focus on particular FSC aspects (e.g. communication, sequence of events, alarming, FSC-FSC communication, etc.). These courses can always be added to the courses mentioned above. For further details please contact your local Honeywell affiliate or Honeywell SMS Regional Delivery Center (RDC). Courses are available for the Honeywell integration centers that are geared to service and training personnel. These training courses can only be given at the HSMS Center of Excellence in 's-Hertogenbosch, the Netherlands, or at the Honeywell integration centers. For further details please contact your local Honeywell affiliate or Honeywell SMS Regional Delivery Center (RDC).
Training courses on specific topics
Courses for Honeywell employees
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Section 11 Decommissioning
Section overview This section discusses the decommissioning of FSC systems. It covers the following topics:
See page
Subsection 11.1 11.2 11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6
Topic
Section overview........................................................................................... 159 Decommissioning overview .......................................................................... 160 Decommissioning procedure ........................................................................ 161 Checking system operation .......................................................................... 161 Powering down the FSC cabinet .................................................................. 161 Disconnecting all cables ............................................................................... 162 Removing all recyclable items ...................................................................... 165 Removing all batteries .................................................................................. 166 Removing the FSC cabinet........................................................................... 166
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11.2 Decommissioning overview

Why decommissioning? Proper decommissioning of an FSC cabinet is required to ensure that everything is disposed of in the most environmentally friendly manner possible. This can be achieved by removing environmentally hazardous materials before destruction of the FSC cabinet. Also, items that can be reused in other FSC cabinets can be removed. It is possible that at the actual time of decommissioning more materials can be recycled than described in this document. This section discusses the decommissioning activities of an FSC cabinet which is installed on site. They are described in accordance with the rules and guidelines that apply in The Netherlands at the time this document was issued. Before decommissioning of an FSC cabinet, make sure that you check the rules and guidelines that apply in the country where the FSC cabinet is located. It is possible that the rules and guidelines have changed since the FSC cabinet was installed. Note: Disposal of environmentally hazardous items should be carried out in accordance with local regulations.
Rules and guidelines
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Section 11: Decommissioning
11.3 Decommissioning procedure

Decommissioning procedure The decommissioning procedure for FSC cabinets consists of the following steps: 1. Check that the process which the FSC system is connected to is no longer operational and has been stopped. 2. Power down the FSC cabinet. 3. Disconnect all cables. 4. Remove all recyclable items. 5. Remove all batteries. 6. Remove the cabinet from the location. Each of these items is discussed in more detail in the following subsections.
11.3.1
Checking system operation
Check process
Make sure that the FSC cabinet is no longer controlling the process. During the decommissioning the Central Part(s) will be stopped. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification.
11.3.2
Powering down the FSC cabinet
Powering down the FSC cabinet
Power down the FSC cabinet as described in Appendix B of this Service Manual. For details on the exact locations of the secondary circuit breakers, secondary disconnectors, primary switches and/or fuse terminals mentioned in Appendix B refer to the general drawings, which are part of the project-related documentation.
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11.3.3
Disconnecting all cables
Cable groups
The cables that enter the FSC cabinet can be divided into four different groups: Power/feeder cables, Field cables, Communication cables, Peripheral equipment, and Earth/grounding cables. These cable types should be disconnected in the above order. Each of them is discussed in more detail below.
Power/feeder cables
Disconnect all incoming AC/DC power/feeder cables from the power distribution panel. Note: If the AC/DC power/feeder cables are not disconnected immediately after powerdown of the FSC cabinet, use a multimeter to verify that the AC/DC power has been disconnected on all incoming fuse terminals and/or main circuit breakers located in the FSC cabinet. The power/feeder cables for AC voltages will be connected to fuse terminals and/or a main circuit breaker located in the FSC cabinet. The power/feeder cables for DC voltages will be connected to fuse terminals located in the FSC cabinet. Insulate the bare wires of the disconnected incoming AC/DC power/feeder cables. This is to prevent dangerous situations which might lead to serious injury of people (e.g. when a circuit breaker in power distribution board is accidentally activated). For details on the exact locations of the fuse terminals and/or main circuit breakers refer to the general drawings, which are part of the project-related documentation.
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Field cables
After disconnecting the power/feeder cables, you may disconnect the field cables. The field cables are used to interconnect the FSC cabinet with other equipment, e.g. marshalling cabinets and/or local panels. Field cables are not directly connected to the I/O modules themselves. This is done using SIC cables which are connected to: FTA-T (to I/O field cables via terminals using SIC-Cs), FTA-E (to interface boards via system cable using SIC-Cs), Terminals (using SIC-Ps), and Third-party devices (using SIC-Cs). The field termination assemblies (FTAs) are electrically passive devices which simply pass incoming or outgoing signals between the field and the I/O module. It is possible that the FTAs and/or terminals are placed remotely (e.g. in a marshalling cabinet). Note: Check all incoming field cables for AC/DC voltages. For potential-free contacts in the FSC cabinet (e.g. relays on FTAs), the power can be supplied from external sources. If AC/DC voltages are still connected to the FSC cabinet, check whether these can be isolated from the external source.
Communication cables
After disconnecting the field cables, you may disconnect the communication cables. The communication modules of the FSC system are placed in the Central Part(s). The communication cables can be divided into three groups: Fiber optic cables, Tap trunk cables, and Other communication cables. For details on which communication cables should be disconnected refer to the communication drawings, which are part of the projectrelated documentation. For details on the exact locations of communication modules and converters refer to the general drawings, which are part of the projectrelated documentation.
Fiber optic cables
Fiber optic cables can be connected in either of three ways: Fiber optic modules (G-interface) are placed in the Central Part(s), Fiber optic converter modules are mounted in the FSC cabinet, or A splice panel is mounted in the FSC cabinet.
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Disconnect the fiber optic cables from the fiber optic modules in the Central Part(s), fiber optic converter modules and/or splice panel in the FSC cabinet.
Tap trunk cables
Taps are mounted in the FSC cabinet for FSCSMM communication with the Honeywell TotalPlant Solution (TPS) system. Note: Make sure that the trunk cables can be disconnected without any problems. (Please note that the trunk cables are routed in a multidrop link via all devices.) Disconnect the trunk cables from the taps mounted in the FSC cabinet. Connect the removed trunk cables via a plug to keep the multidrop link intact.
Other communication cables
All other communication cables are connected to communication modules located in the FSC cabinet. Note: Make sure that the communication cables can be disconnected without any problems. (Please note that the FSC cabinet being decommissioned may be part of a multidrop communication link.) Disconnect all communication cables that are connected to the communication modules in the FSC cabinet.
Peripheral equipment
After disconnecting the communication cables, you may disconnect all cables between the FSC cabinet and external communication devices. Check whether all peripheral equipment connected to the FSC cabinet such as the FSC user station and/or SOE station (including printers) can be removed and used for other purposes. The FSC user station and/or SOE station can only be removed if they are not used by other devices. Note: The FSC user station and/or SOE station should be disposed of in accordance with local regulations. For decommissioning information for external devices connected to FSC cabinets refer to the manufacturer's information.
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Earth/grounding cables
After disconnecting the cables between the FSC cabinet and external communication devices, you may disconnect the earth/grounding cables. Three different earth bars may be present in FSC cabinet: Safety earth/ground, Instrument earth/ground (also called master reference ground, or MRG), and Ex(i) earth/ground.
Safety earth/ground
All mechanical parts of the FSC cabinet are connected to the safety earth/ground bar, which is installed in the FSC cabinet to ensure correct operation. The cable of the plant safety earth/ground can be disconnected from the safety earth/ground bar or a safety earth/ground bolt in the FSC cabinet. The instrument earth/ground bar is used for connections of the shield from field cables and the instrument earth/ground wire from the communication boards. The cable of the plant instrument earth/ground can be disconnected from the instrument earth/ground bar in the FSC cabinet.
Ex(i) earth/ground
The Ex(i) earth/ground bar is used for the earth connection of Ex(i) equipment. The cable of the plant Ex(i) earth/ground can be disconnected from the Ex(i) earth/ground bar in the FSC cabinet.
11.3.4
Removing all recyclable items
Recyclable items
Remove all recyclable items from the FSC cabinet. These include the Central Part modules, I/O modules, FTAs and SIC cables, which can be used as spare parts for other FSC cabinets. Visually inspect the items removed for any damage. Items that are damaged in any way should not be used as spare parts. Test the removed items using an FSC simulation and training unit (see Appendix H of the FSC Software Manual). Removed items should be properly packed.
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Note: All spare parts should be tested every three months as part of preventive maintenance. If removed items are to be used as spare parts, make sure they are entered into the preventivemaintenance procedure and tested quarterly.
11.3.5
Removing all batteries
Batteries
Remove all batteries from the FSC cabinet. Batteries can be found in the following modules: Diagnostic and Battery Module (DBM, HSMS type 10006/x/x), and Single Bus Driver (SBD, HSMS type 10007/x/x). Both of these modules are placed in the Central Part(s) of the FSC cabinet. Notes: 1. You should never place DBMs and SBDs flat on a conductive surface. The batteries placed on the DBM or SBD may then cause a short circuit which will damage the module beyond repair. 2. Always place DBMs and SBDs straight up or in their original packaging. 3. Environmentally hazardous items, such as batteries, should be disposed of in accordance with local regulations.
11.3.6
Removing the FSC cabinet
Removing the FSC cabinet
FSC cabinets are bolted down to the floor. After all the activities described in the previous subsections have been completed, these bolts may be removed. Make sure that the swing frame and doors are closed to prevent the FSC cabinet from tipping over. Otherwise hazardous situations may arise which may lead to serious injury to people.
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Appendix A of this Service Manual shows the locations of the bolt-down holes. For moving and hoisting instructions refer to Section 2 of this Service Manual. Note: Environmentally hazardous items should be disposed of in accordance with local regulations.
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Appendix A Plinth Layouts

A.1 Section overview
This appendix provides detailed information on the measurements and locations of the bolt-down holes that are used to secure FSC cabinets to the floor. FSC cabinets can be delivered with or without plinths.
See page
Section overview
Subsection A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8 A.9 A.10 A.11
Topic
Section overview........................................................................................... 169 Introduction ................................................................................................... 170 No plinth for one PS 4806 cabinet................................................................ 171 Plinth for one PS 4806 cabinet ..................................................................... 172 Plinth for two PS 4806 cabinets.................................................................... 173 Plinth for three PS 4806 cabinets ................................................................. 174 No plinth for one PS 4808 cabinet................................................................ 175 Plinth for one PS 4808 cabinet ..................................................................... 176 Plinth for two PS 4808 cabinets.................................................................... 177 Plinth for three PS 4808 cabinets ................................................................. 178 Plinth for four PS 4808 cabinets ................................................................... 179
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A.2
Introduction
Two standard Rittal cabinets types are used for FSC cabinets: PS 4806: Measurements: 80 x 60 x 200 cm (width x depth x height) (31 x 23 x 78 in). PS 4808: Measurements: 80 x 80 x 200 cm (width x depth x height) (31 x 31 x 78 in). The standard plinth mounted below an FSC cabinet is 100 mm high (4 inches).
Measurements
Plinths
The following plinths are available for the Rittal cabinets: PS 4806: 100 mm (approx. 4 in) high: model no. SO 2833.200 200 mm (approx. 8 in) high: model no. SO 2834.200 PS 4808: 100 mm (approx. 4 in) high: model no. SO 2848.200 200 mm (approx. 8 in) high: model no. SO 2849.200
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Appendix A: Plinth Layouts
A.3
No plinth for one PS 4806 cabinet

Figure A-1 below shows the dimensions and locations of the bolt-down holes that are used for securing a Rittal PS 4806 cabinet without a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
One PS 4806, no plinth
Figure A-1 No plinth for one Rittal PS 4806 cabinet

The measurements in the drawing are: T = 550 mm (approx. 21.7 in) B = 800 mm (approx. 31.5 in)
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A.4
Plinth for one PS 4806 cabinet

Figure A-2 below shows the dimensions and locations of the bolt-down holes that are used for securing a Rittal PS 4806 cabinet with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
One PS 4806, plinth
Figure A-2 Plinth for one Rittal PS 4806 cabinet

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A.5
Plinth for two PS 4806 cabinets

Figure A-3 below shows the dimensions and locations of the bolt-down holes that are used for securing two Rittal PS 4806 cabinets with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
Two PS 4806, plinth
Figure A-3 Plinth for two Rittal PS 4806 cabinets
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A.6
Plinth for three PS 4806 cabinets

Figure A-4 below shows the dimensions and locations of the bolt-down holes that are used for securing three Rittal PS 4806 cabinets with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
Three PS 4806, plinth
Figure A-4 Plinth for three Rittal PS 4806 cabinets
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A.7
No plinth for one PS 4808 cabinet

Figure A-5 below shows the dimensions and locations of the bolt-down holes that are used for securing a Rittal PS 4808 cabinets without a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
One PS 4808, no plinth
Figure A-5 No plinth for one Rittal PS 4808 cabinet

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A.8
Plinth for one PS 4808 cabinet

Figure A-6 below shows the dimensions and locations of the bolt-down holes that are used for securing a Rittal PS 4808 cabinet with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
One PS 4808, plinth
Figure A-6 Plinth for one Rittal PS 4808 cabinet

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A.9
Plinth for two PS 4808 cabinets

Figure A-7 below shows the dimensions and locations of the bolt-down holes that are used for securing two Rittal PS 4808 cabinets with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
Two PS 4808, plinth
Figure A-7 Plinth for two Rittal PS 4808 cabinets
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A.10
Plinth for three PS 4808 cabinets

Figure A-8 below shows the dimensions and locations of the bolt-down holes that are used for securing three Rittal PS 4808 cabinets with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
Three PS 4808, plinth
Figure A-8 Plinth for three Rittal PS 4808 cabinets
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A.11
Plinth for four PS 4808 cabinets

Figure A-9 below shows the dimensions and locations of the bolt-down holes that are used for securing four Rittal PS 4808 cabinets with a plinth to the floor. All measurements are in millimeters (1 inch = 25.4 mm).
Four PS 4808, plinth
Figure A-9 Plinth for four Rittal PS 4808 cabinets
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Appendix B Stopping / Powering Down the FSC System

B.1 Section overview
This appendix provides detailed information on how to stop an FSC system and power down an FSC cabinet. It covers the following topics:
Topic See page
Section
Subsection B.1 B.2 B.3 B.4 B.5 B.6 B.7
Section overview........................................................................................... 181 Central Part configuration ............................................................................. 182 Stopping one CP of an FSC system with redundant CPs ............................ 183 Stopping both CPs of an FSC system with redundant CPs ......................... 185 Powering down an FSC system with redundant CPs ................................... 188 Stopping the CP of an FSC system with a single CP................................... 192 Powering down an FSC system with a single CP......................................... 194
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B.2 Central Part configuration

Central Part configuration
There are basically two Central Part (CP) configurations: Single Central Part (1oo1D), and Redundant Central Parts (1oo2D). Depending on the FSC Central Part configuration (single or redundant), one of the following procedures should be followed: Stopping one Central Part of an FSC system with redundant Central Parts (see subsection B.3), Stopping both Central Parts of an FSC system with redundant Central Parts (see subsection B.4), Powering down an FSC system with redundant Central Parts (see subsection B.5), Stopping the CP of an FSC system with a single Central Part (see subsection B.6), and Powering down an FSC system with a single Central Part (see subsection B.7). Each of these procedures is discussed in more detail in the following sections. Notes: 1. Before starting a procedure to perform a stop of an FSC system and/or powerdown of an FSC cabinet, make sure that the FSC system is no longer controlling the process. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification. 2. If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically.
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Appendix B: Stopping / Powering Down the FSC System
B.3 Stopping one CP of an FSC system with redundant CPs

Stopping one CP in redundant system This section describes the correct procedure to stop one Central Part of an FSC system with redundant Central Parts. Notes: 1. After completion of this procedure, one Central Part will be stopped. Use the Extended Diagnostics option of the FSC Navigator software to verify that the other Central Part is fully operational before continuing with this procedure. 2. During the time that one of the Central Parts of an FSC system with redundant Central Parts is stopped, the FSC system is not running with increased or high availability.
Procedure
The procedure below contains the description "Central Part". This can be Central Part 1 or Central Part 2, depending on the Central Part to be stopped. To stop one of the Central Parts, follow the procedure below.
Step 1
Check if the Central Part is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If the Central Part is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) should either be blank or not flashing.
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Step 2
If not all conditions of Step 1 above are met, the Central Part should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in the Central Part from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place. b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in the Central Part, to the horizontal position. Wait for two seconds and return the key to its vertical position. The Central Part has now stopped and the conditions mentioned in Step 1 above should be met. Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the horizontal position ("STOP"). Identify which circuit breaker in the circuit breaker rack supplies the 24 Vdc power to the Central Part that is being stopped, and switch it off. Notes: 1. If is essential that the correct circuit breaker is deactivated. If the incorrect circuit breaker is deactivated, this might result in a stop of the redundant Central Part. Stopping both Central Parts when the FSC system is still controlling the process may lead to dangerous situations. 2. For details on the exact location of the 24 Vdc circuit breaker refer to the general drawings, power distribution drawings and rack layout, which are all part of the projectrelated documentation. At this point, one Central Part of the FSC system with redundant Central Parts has been successfully stopped.
Step 3
Step 4
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B.4 Stopping both CPs of an FSC system with redundant CPs

Stopping both CPs in redundant system
This section describes the correct procedure to stop both Central Parts of an FSC system with redundant Central Parts. Note: After completion of this procedure, both Central Parts will be stopped. Before starting the procedure, make sure that the FSC system is no longer controlling the process. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification.
Procedure
Step 1
To stop the Central Parts, follow the procedure below. Check if Central Part 1 is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If Central Part 1 is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in Central Part 1 should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 1 should either be blank or not flashing.
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Step 2
If not all conditions of Step 1 above are met, Central Part 1 should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in Central Part 1 from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place. b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in Central Part 1, to the horizontal position. Wait for two seconds and return the key to its vertical position. Central Part 1 has now stopped and the conditions mentioned in Step 1 above should be met. Check if Central Part 2 is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If Central Part 2 is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in Central Part 2 should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 2 should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 2 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 2 should either be blank or not flashing. If not all conditions of Step 3 above are met, Central Part 2 should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in Central Part 2 from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place.
Step 3
Step 4
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b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in Central Part 2, to the horizontal position. Wait for two seconds and return the key to its vertical position. Central Part 2 has now stopped and the conditions mentioned in Step 3 above should be met. Turn the key switches of the Central Processing Units (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Parts 1 and 2 to their horizontal position ("STOP"). Identify which circuit breakers in the circuit breaker rack supply the 24 Vdc power to Central Parts 1 and 2, and switch them off. Note: For details on the exact location of the 24 Vdc circuit breakers refer to the general drawings, power distribution drawings and rack layout, which are all part of the project-related documentation. At this point, both Central Parts of the FSC system with redundant Central Parts have been successfully stopped.
Step 5
Step 6
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B.5 Powering down an FSC system with redundant CPs

Powering down redundant system This section describes the correct procedure to power down an FSC system with redundant Central Parts. Note: After completion of this procedure, both Central Parts will be stopped and the FSC system will be powered down. Before starting the procedure, make sure that the FSC system is no longer controlling the process. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification.
Procedure
To power down an FSC system with redundant Central Parts, follow the procedure below.
Step 1
Check if Central Part 1 is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If Central Part 1 is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in Central Part 1 should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 1 should either be blank or not flashing.
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Step 2
If not all conditions of Step 1 above are met, Central Part 1 should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in Central Part 1 from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and reconnect the flatcable. b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in Central Part 1, to the horizontal position. Wait for two seconds and return the key to its vertical position. Central Part 1 has now stopped and the conditions mentioned in Step 1 above should be met. Check if Central Part 2 is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If Central Part 2 is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in Central Part 2 should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 2 should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 2 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 2 should either be blank or not flashing. If not all conditions of Step 3 above are met, Central Part 2 should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in Central Part 2 from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place.
Step 3
Step 4
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b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in Central Part 2, to the horizontal position. Wait for two seconds and return the key to its vertical position. Central Part 2 has now stopped and the conditions mentioned in Step 3 above should be met.
Step 5
Turn the key switches of the Central Processing Units (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Parts 1 and 2 to their horizontal position ("STOP"). Switch off all circuit breakers in the circuit breaker rack. Switch off all primary switches of the power supply units (PSUs) mounted in the FSC cabinet. Switch off all main circuit breakers mounted in the FSC cabinet. Switch off all secondary disconnectors of the PSUs mounted in the FSC cabinet. Remove all fuses from the incoming fuse terminals which the AC/DC power/feeder cables are connected to. Switch off all circuit breakers in the power distribution panel which provides AC/DC power to the FSC cabinet. Use a multimeter to check that the power has been disconnected on all incoming power/feeder terminals/main circuit breakers. At this point both Central Parts have stopped and the FSC cabinet has been successfully powered down. Note: For details on the exact location of the 24 Vdc circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, power distribution drawings and rack layout, which are all part of the project-related documentation.
Step 6
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
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At this point, both Central Parts of the FSC system with redundant Central Parts are stopped and the FSC cabinet has been successfully powered down.
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B.6 Stopping the CP of an FSC system with a single CP

Stopping CP in single system This section describes the correct procedure to stop the Central Part of an FSC system with a single Central Part. Note: After completion of this procedure, the Central Part will be stopped. Before starting the procedure, make sure that the FSC system is no longer controlling the process. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification.
Procedure
Step 1
To stop the Central Part, follow the procedure below. Check if the Central Part is already stopped. Note: If any errors have been detected by the FSC system, it is possible that one or both Central Parts have already stopped automatically. If the Central Part is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) should either be blank or not flashing.
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Step 2
If not all conditions of Step 1 above are met, the Central Part should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in the Central Part from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place. b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in the Central Part, to the horizontal position. Wait for two seconds and return the key to its vertical position. The Central Part has now stopped and the conditions mentioned in Step 1 above should be met. Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the horizontal position ("STOP"). Identify which circuit breaker in the circuit breaker rack supplies the 24 Vdc power to the Central Part, and switch it off. Note: For details on the exact location of the 24 Vdc circuit breaker refer to the general drawings, power distribution drawings and rack layout, which are all part of the project-related documentation. At this point, the Central Part of the FSC system with a single Central Part has been successfully stopped.
Step 3
Step 4
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B.7 Powering down an FSC system with a single CP

Powering down single system This section describes the correct procedure to power down an FSC system with a single Central Part. Note: After completion of this procedure, the Central Part will be stopped and the FSC system will be powered down. Before starting the procedure, make sure that the FSC system is no longer controlling the process. Stopping the Central Part(s) when the FSC system is still controlling the process may lead to dangerous situations. Contact the operators for verification.
Procedure
To power down an FSC system with a single Central Part, follow the procedure below.
Step 1
Check if the Central Part is already stopped. Note: If any errors have been detected by the FSC system, it is possible that the Central Part has already stopped automatically. If the Central Part is stopped, all of the following conditions should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in the Central Part should be off. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be off. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be off. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part should either be blank or not flashing.
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Step 2
If not all conditions of Step 1 above are met, the Central Part should be stopped manually. This can be done in either of two ways: a) Pull the flatcable of the watchdog module (HSMS type 10005/x/x) in the Central Part from the watchdog horizontal bus (HSMS type 10005/O/1), which is located above the Central Part. Wait for two seconds and put the flatcable back into place. b) Switch the key of the watchdog horizontal bus (HSMS type 10005/O/2), located in the Central Part, to the horizontal position. Wait for two seconds and return the key to its vertical position. The Central Part has now stopped and the conditions mentioned in Step 1 above should be met. Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the horizontal position ("STOP"). Switch off all circuit breakers in the circuit breaker rack. Switch off all primary switches of the power supply units (PSUs) mounted in the FSC cabinet. Switch off all main circuit breakers mounted in the FSC cabinet. Switch off all secondary disconnectors of the PSUs mounted in the FSC cabinet. Remove all fuses from the incoming fuse terminals which the AC/DC power/feeder cables are connected to. Switch off all circuit breakers in the power distribution panel which provides AC/DC power to the FSC cabinet. Use a multimeter to check that the power has been disconnected on all incoming power/feeder terminals/main circuit breakers.
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Step 10
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Note: For details on the exact location of the 24 Vdc circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, the Central Part of the FSC system with a single Central Parts is stopped and the FSC cabinet has been successfully powered down.
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Appendix C Starting Up / Powering Up the FSC System

C.1 Section overview
This appendix provides detailed information on how to start an FSC system and power up an FSC cabinet. It covers the following topics:
Topic See page
Section
Subsection C.1 C.2 C.3 C.4 C.5 C.6 C.7
Section overview........................................................................................... 197 Central Part configuration ............................................................................. 198 Starting one CP of an FSC system with redundant CPs .............................. 199 Starting both CPs of an FSC system with redundant CPs ........................... 203 Powering up an FSC system with redundant CPs ....................................... 209 Starting the CP of an FSC system with a single CP..................................... 215 Powering up an FSC system with a single CP ............................................. 218
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C.2 Central Part configuration

Central Part configuration
There are basically two Central Part (CP) configurations: Single Central Part (1oo1D), and Redundant Central Parts (1oo2D). Depending on the FSC Central Part configuration (single or redundant), one of the following procedures should be followed: Starting one Central Part of an FSC system with redundant Central Parts (see subsection C.3), Starting both Central Parts of an FSC system with redundant Central Parts (see subsection C.4), Powering up an FSC system with redundant Central Parts (see subsection C.5), Starting the CP of an FSC system with a single Central Part (see subsection C.6), and Powering up an FSC system with a single Central Part (see subsection C.7). Each of these procedures is discussed in more detail in the following sections.
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Appendix C: Starting Up / Powering Up the FSC System
C.3 Starting one CP of an FSC system with redundant CPs

Starting one CP in redundant system This section describes the correct procedure to start one Central Part of an FSC system with redundant Central Parts. Notes: 1. It is assumed that the Central Part has been stopped in accordance with the procedure as described in Appendix B of this Service Manual. 2. It is assumed that the other Central Part is already fully operational. If this is not the case, start both Central Parts in accordance with the procedure as described in section C.4. Checks Before starting the Central Part, make sure you verify the following: All circuit breakers are on. (It is possible that the 24 Vdc circuit breaker for the Central Part is off. If that is the case, leave this circuit breaker off). The key on the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part is in the horizontal position ("STOP"). For watchdog horizontal bus 10005/O/1: The flatcables of the watchdog module (WD, HSMS type 10005/x/x) in the Central Part are properly connected to the watchdog horizontal bus (10005/O/1), which is located above the Central Part. For watchdog horizontal bus 10005/O/2: The key of the watchdog horizontal bus (10005/O/2), which is located above the Central Part, is in the horizontal position. To start one Central Part of an FSC system with redundant Central Parts, follow the procedure below. It contains the description "Central Part". This can be Central Part 1 or Central Part 2, depending on the Central Part to be started.
Step 1
Procedure
Activate the 24 Vdc circuit breaker for the Central Part. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time).
Step 2
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Step 3
Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 4 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 5 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 4
Depending on the FSC configuration, there are three possibilities: a) The FSC system has been configured for EPROM mode. In that case, proceed with step 5 below. b) The FSC system has been configured for RAM mode. The RAM chips are placed on the CPU module. If the CPU and/or DBM have been removed from the Central Part, the information stored in the RAM chips is lost. The FSC application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After the FSC application has been downloaded successfully, proceed with step 5 below. c) The FSC system has been configured for FLASH mode. (Please note that this requires special Central Part modules that support flash memory operation.) The application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After all the software has been downloaded successfully, proceed with step 5 below. If the Central Part contains an FSC Safety Manager Module (FSC-SMM, HSMS type 100x8/2/U), the Personality Image (PI) for the Central Part should be loaded from the TPS system. For details on how to load the PI refer to Appendix D of the FSC Software Manual ("On-Line Modification") or the TPS user manuals.
Step 5
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Step 6
Cycle the WD reset key switch, which is located in one of the Central Parts. Check if the Central Part is running. If it is running, all of the following requirements should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in the Central Part should be on. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be on. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part should show the current time and should be flashing or steady. If not all conditions of step 7 above are met, the FSC system has detected an error which prevents the Central Part from starting up. In that case, use the "Extended Diagnostics" option of the FSC Navigator software to retrieve detailed error information from the FSC system. Any errors found need to be resolved before the WD reset key switch as mentioned in step 6 may be activated again. Repeat the above steps until the Central Part is operational. Check the status of the DBM. There are two possibilities: a) If all conditions of step 7 above are met and the DBM displays of Central Part 1 and Central Part 2 are steady, the FSC system is fully operational. b) If all conditions of step 7 above are met and the DBM displays of Central Part 1 and Central Part 2 are flashing, an alarm/error has been detected in the FSC system. Use the "Extended Diagnostics" option of the FSC Navigator software to retrieve information from the FSC system. Resolve the reported alarm(s)/error(s) and activate the WD reset key switch again. Repeat step 10 until the FSC system is fully operational without any errors.
Step 7
Step 8
Step 9
Step 10
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Note: For details on the exact location of the (main) circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, one Central Part of the FSC system with redundant Central Parts has successfully started up.
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C.4 Starting both CPs of an FSC system with redundant CPs

Starting both CPs in redundant system This section describes the correct procedure to start both Central Parts of an FSC system with redundant Central Parts. Note: It is assumed that both Central Parts have been stopped in accordance with the procedure as described in Appendix B of this Service Manual. Checks Before starting the Central Part, make sure you verify the following: All circuit breakers in the power distribution panel are on. All fuses are placed in the incoming fuse terminals which the AC/DC power/feeder cables are connected to. All secondary disconnectors of the power supply units (PSUs) are on. All main circuit breakers are on. All primary switches of the PSUs are on. All circuit breakers are on. (It is possible that the 24 Vdc circuit breakers for both Central Parts are off. If that is the case, leave these circuit breakers off). The keys on the Central Processing Units (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Parts is in the horizontal position ("STOP"). For watchdog horizontal bus 10005/O/1: The flatcables of the watchdog modules (WD, HSMS type 10005/x/x) in the Central Parts are properly connected to the watchdog horizontal buses (10005/O/1), which are located above the Central Parts. For watchdog horizontal bus 10005/O/2: The keys of the watchdog horizontal buses (10005/O/2), which are located above the Central Parts, are in the horizontal position.
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Procedure
To start both Central Parts of a redundant FSC system, follow the procedure below.
Step 1
Activate the 24 Vdc circuit breaker for Central Part 1. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 1 can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Part 1 to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 4 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 5 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 2
Step 3
Step 4
Depending on the FSC configuration, there are three possibilities: a) The FSC system has been configured for EPROM mode. In that case, proceed with step 5 below. b) The FSC system has been configured for RAM mode. The RAM chips are placed on the CPU module. If the CPU and/or DBM have been removed from the Central Part, the information stored in the RAM chips is lost. The FSC application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After the FSC application has been downloaded successfully, proceed with step 5 below. c) The FSC system has been configured for FLASH mode. (Please note that this requires special Central Part modules that support flash memory operation.) The application will then need to be
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loaded using the "Load Software" option of the FSC Navigator software. After all the software has been downloaded successfully, proceed with step 5 below.
Step 5
If Central Part 1 contains an FSC Safety Manager Module (FSC-SMM, HSMS type 100x8/2/U), the Personality Image (PI) for the Central Part should be loaded from the TPS system. For details on how to load the PI refer to Appendix D of the FSC Software Manual ("On-Line Modification") or the TPS user manuals. Cycle the WD reset key switch, which is located in one of the Central Parts. Check if Central Part 1 is running. If it is running, all of the following requirements should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in Central Part 1 should be on. It is possible that Central Part 1 contains more than one VBD. In that case the 'On' LED of all VBDs should be on. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be on. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in Central Part 1 should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 1 should show the current time and should be flashing or steady. If not all conditions of step 7 above are met, the FSC system has detected an error which prevents Central Part 1 from starting up. In that case, use the "Extended Diagnostics" option of the FSC Navigator software to retrieve detailed error information from the FSC system. Any errors found need to be resolved before the WD reset key switch as mentioned in step 6 may be activated again. Repeat the above steps until Central Part 1 is operational.
Step 6
Step 7
Step 8
Step 9
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Step 10
Activate the 24 Vdc circuit breaker for Central Part 2. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 2 can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Part 2 to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 13 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 14 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 11
Step 12
Step 13
Depending on the FSC configuration, there are three possibilities: a) The FSC system has been configured for EPROM mode. In that case, proceed with step 14 below. b) The FSC system has been configured for RAM mode. The RAM chips are placed on the CPU module. If the CPU and/or DBM have been removed from the Central Part, the information stored in the RAM chips is lost. The FSC application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After the FSC application has been downloaded successfully, proceed with step 14 below. c) The FSC system has been configured for FLASH mode. (Please note that this requires special Central Part modules that support flash memory operation.) The application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After all the software has been downloaded successfully, proceed with step 14 below.
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Step 14
Step 15
Step 16
Step 17
Step 18
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Step 19
Check the status of the DBM. There are two possibilities: a) If all conditions of steps 7 and 16 above are met and the DBM displays of Central Part 1 and Central Part 2 are steady, the FSC system is fully operational. b) If all conditions of steps 7 and 16 above are met and the DBM displays of Central Part 1 and Central Part 2 are flashing, an alarm/error has been detected in the FSC system. Use the "Extended Diagnostics" option of the FSC Navigator software to retrieve information from the FSC system. Resolve the reported alarm(s)/error(s) and activate the WD reset key switch again. Repeat step 19 until the FSC system is fully operational without any errors. Note: For details on the exact location of the (main) circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, both Central Parts of the FSC system with redundant Central Parts have successfully started up.
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C.5 Powering up an FSC system with redundant CPs

Powering up FSC system with redundant CPs
This section describes the correct procedure to power up an FSC system with redundant Central Parts. Note: It is assumed that the FSC cabinet with redundant Central Parts has been powered down in accordance with the procedure as described in Appendix B of this Service Manual.
Procedure
To power up an FSC system with redundant Central Parts, follow the procedure below.
Step 1
Turn the key switches of the Central Processing Units (CPU, HSMS type 10002/x/x or 10012/x/x) in both Central Parts to the horizontal position ("STOP"). For watchdog horizontal bus 10005/O/1: Make sure that the flatcables of the watchdog modules (WD, HSMS type 10005/x/x) in both Central Parts are properly connected to the watchdog horizontal buses (10005/O/1), which are located above the Central Parts. For watchdog horizontal bus 10005/O/2: Make sure that the keys of the watchdog horizontal buses (10005/O/2), which are located above the Central Parts, are in the horizontal position.
Step 2
Step 3
Switch on all circuit breakers in the power distribution panel. Place all fuses in the incoming fuse terminals which the AC/DC power/feeder cables are connected to. Switch on all secondary disconnectors of the power supply units (PSUs). Switch on all main circuit breakers.
Step 4
Step 5
Step 6
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Step 7
Switch on all primary switches of the PSUs. Switch on all circuit breakers located in the circuit breaker rack. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 1 can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Part 1 to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 11 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 12 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 8
Step 9
Step 10
Step 11
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Step 12
Step 13
Step 14
Step 15
Step 16
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Step 17
At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in Central Part 2 can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in Central Part 2 to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 19 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 20 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 18
Step 19
Depending on the FSC configuration, there are three possibilities: a) The FSC system has been configured for EPROM mode. In that case, proceed with step 20 below. b) The FSC system has been configured for RAM mode. The RAM chips are placed on the CPU module. If the CPU and/or DBM have been removed from the Central Part, the information stored in the RAM chips is lost. The FSC application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After the FSC application has been downloaded successfully, proceed with step 20 below. c) The FSC system has been configured for FLASH mode. (Please note that this requires special Central Part modules that support flash memory operation.) The application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After all the software has been downloaded successfully, proceed with step 20 below.
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Step 20
Step 21
Step 22
Step 23
Step 24
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Step 25
Check the status of the DBM. There are two possibilities: a) If all conditions of steps 14 and 22 above are met and the DBM displays of Central Part 1 and Central Part 2 are steady, the FSC system is fully operational. b) If all conditions of steps 14 and 22 above are met and the DBM displays of Central Part 1 and Central Part 2 are flashing, an alarm/error has been detected in the FSC system. Use the "Extended Diagnostics" option of the FSC Navigator software to retrieve information from the FSC system. Resolve the reported alarm(s)/error(s) and activate the WD reset key switch again. Repeat step 25 until the FSC system is fully operational without any errors. Note: For details on the exact location of the (main) circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, the FSC system with redundant Central Parts has successfully powered up.
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C.6 Starting the CP of an FSC system with a single CP

Starting CP in single system This section describes the correct procedure to start the Central Part of an FSC system with a single Central Part. Note: It is assumed that the Central Part has been stopped in accordance with the procedure as described in Appendix B of this Service Manual. Procedure To start the Central Part of an FSC system with a single Central Part, follow the procedure below.
Step 1
Activate the 24 Vdc circuit breaker for the Central Part. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 4 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 5 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 2
Step 3
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Step 4
Depending on the FSC configuration, there are three possibilities: a) The FSC system has been configured for EPROM mode. In that case, proceed with step 5 below. b) The FSC system has been configured for RAM mode. The RAM chips are placed on the CPU module. If the CPU and/or DBM have been removed from the Central Part, the information stored in the RAM chips is lost. The FSC application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After the FSC application has been downloaded successfully, proceed with step 5 below. c) The FSC system has been configured for FLASH mode. (Please note that this requires special Central Part modules that support flash memory operation.) The application will then need to be loaded using the "Load Software" option of the FSC Navigator software. After all the software has been downloaded successfully, proceed with step 5 below. If the Central Part contains an FSC Safety Manager Module (FSC-SMM, HSMS type 100x8/2/U), the Personality Image (PI) for the Central Part should be loaded from the TPS system. For details on how to load the PI refer to Appendix D of the FSC Software Manual ("On-Line Modification") or the TPS user manuals. Cycle the WD reset key switch, which is located in the Central Part. Check if the Central Part is running. If it is running, all of the following requirements should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in the Central Part should be on. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be on. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part should show the current time and should be flashing or steady.
Step 5
Step 6
Step 7
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Step 8
If not all conditions of step 7 above are met, the FSC system has detected an error which prevents the Central Part from starting up. In that case, use the "Extended Diagnostics" option of the FSC Navigator software to retrieve detailed error information from the FSC system. Any errors found need to be resolved before the WD reset key switch as mentioned in step 6 may be activated again. Repeat the above steps until the Central Part is operational. Check the status of the DBM. There are two possibilities: a) If all conditions of step 7 above are met and the DBM displays of the Central Part are steady, the FSC system is fully operational. b) If all conditions of step 7 above are met and the DBM displays of the Central Part are flashing, an alarm/error has been detected in the FSC system. Use the "Extended Diagnostics" option of the FSC Navigator software to retrieve information from the FSC system. Resolve the reported alarm(s)/error(s) and activate the WD reset key switch again. Repeat step 10 until the FSC system is fully operational without any errors. Note: For details on the exact location of the (main) circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, the Central Part of the FSC system with a single Central Part has successfully started up.
Step 9
Step 10
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C.7 Powering up an FSC system with a single CP

Powering up FSC system with single CP
This section describes the correct procedure to power up an FSC system with a single Central Part. Note: It is assumed that the FSC cabinet with a single Central Part has been powered down in accordance with the procedure as described in Appendix B of this Service Manual.
Procedure
Step 1
To power up an FSC system with a single Central Part, follow the procedure below. Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the horizontal position ("STOP"). For watchdog horizontal bus 10005/O/1: Make sure that the flatcable of the watchdog module (WD, HSMS type 10005/x/x) in the Central Part is properly connected to the watchdog horizontal bus (10005/O/1), which is located above the Central Part. For watchdog horizontal bus 10005/O/2: Make sure that the key of the watchdog horizontal bus (10005/O/2), which is located above the Central Part, is in the horizontal position.
Step 3
Step 2
Switch on all circuit breakers in the power distribution panel. Place all fuses in the incoming fuse terminals which the AC/DC power/feeder cables are connected to. Switch on all secondary disconnectors of the power supply units (PSUs). Switch on all main circuit breakers.
Step 4
Step 5
Step 6
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Step 7
Switch on all primary switches of the PSUs. Switch on all circuit breakers located in the circuit breaker rack. At this point the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part can be in either of the following states: a) The displays of the DBM are blank, or b) The displays of the DBM show a time (not necessarily the actual time). Turn the key switch of the Central Processing Unit (CPU, HSMS type 10002/x/x or 10012/x/x) in the Central Part to the vertical position ("RUN"). At this point there are two possibilities: a) If the DBM and/or CPU have been removed from the Central Part, the displays of the DBM will remain blank and the application needs to be downloaded (see step 11 below). b) The VBDs will click (the "On" LED goes on for a short period), and after some time the displays of the DBM show a time (not necessarily the actual time), which is updated continuously. You can now proceed with step 12 below. Note: Depending on the FSC configuration and size of the application, it may take some time before the displays of the DBM are updated.
Step 8
Step 9
Step 10
Step 11
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Step 12
If the Central Part contains an FSC Safety Manager Module (FSC-SMM, HSMS type 100x8/2/U), the Personality Image (PI) for the Central Part should be loaded from the TPS system. For details on how to load the PI refer to Appendix D of the FSC Software Manual ("On-Line Modification") or the TPS user manuals. Cycle the WD reset key switch, which is located in the Central Part. Check if the Central Part is running. If it is running, all of the following requirements should be met: a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type 10001/x/x) in the Central Part should be on. It is possible that the Central Part contains more than one VBD. In that case the 'On' LED of all VBDs should be on. b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. c) The 'ESD' LED on the watchdog module (HSMS type 10005/x/x) in the Central Part should be on. d) The displays of the Diagnostic and Battery Module (DBM, HSMS type 10006/x/x) in the Central Part should show the current time and should be flashing or steady. If not all conditions of step 14 above are met, the FSC system has detected an error which prevents the Central Part from starting up. In that case, use the "Extended Diagnostics" option of the FSC Navigator software to retrieve detailed error information from the FSC system. Any errors found need to be resolved before the WD reset key switch as mentioned in step 13 may be activated again. Repeat the above steps until the Central Part is operational.
Step 13
Step 14
Step 15
Step 16
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Step 17
Check the status of the DBM. There are two possibilities: a) If all conditions of step 14 above are met and the DBM displays of the Central Part are steady, the FSC system is fully operational. b) If all conditions of step 14 above are met and the DBM displays of the Central Part are flashing, an alarm/error has been detected in the FSC system. Use the "Extended Diagnostics" option of the FSC Navigator software to retrieve information from the FSC system. Resolve the reported alarm(s)/error(s) and activate the WD reset key switch again. Repeat step 18 until the FSC system is fully operational without any errors. Note: For details on the exact location of the (main) circuit breakers, secondary disconnectors, primary switches and fuse terminals refer to the general drawings, which are part of the projectrelated documentation. At this point, the FSC system with a single Central Part has successfully powered up.
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Appendix D Alarm/Error Messages and Solutions

D.1
Section
Section overview
This appendix provides detailed information on the alarm/error messages generated by the FSC system. In addition to the alarm/error messages, information on the reasons for the alarm/error is provided as well as possible solution to resolve them.
Topic See page
Subsection D.1 D.2 D.3 D.4 D.5 D.6 D.7 D.8 D.9 D.10
Section overview........................................................................................... 223 General messages........................................................................................ 224 Analog input module 10102/x/x .................................................................... 225 Analog input module 10105/2/1.................................................................... 226 Analog output module 10205/2/1.................................................................. 227 Communication errors with the FSC user station ......................................... 228 Output short circuit........................................................................................ 229 Download not successful .............................................................................. 230 Process trip during an on-line modification................................................... 231 Calculation errors.......................................................................................... 232
For further details on the alarm/error messages generated by the FSC system refer to the FSC Software Manual.
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D.2
General messages
Table D-1 below shows a number of general alarm/error messages which are not related to specific modules. Table D-1 General, non module-specific messages
General messages
"APPLICATION NOT YET LOADED" Reason 1. The application has not been loaded into the FSC system. Possible solution Use the "Download Software" option of the FSC Navigator software to download the application into the FSC system.
"JUMPER SETTING COM MODULE ON SYSTEM BUS NOT CORRECT" Reason 1. The communication modules have been removed from the Central Part and have not been placed back at the correct module position. A communication module has been added or removed, and the jumper setting at the rear of the system bus has not been updated. Possible solution Check the placement of all Central Part modules according to the project-related documentation. Check the jumper settings at the rear of the system bus. Check the jumper setting at the rear of the system bus.
2.
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Appendix D: Alarm/Error Messages and Solutions
D.3
Analog input module 10102/x/x

Table D-2 below shows the most common alarm/error messages related to the 10102/x/x analog input modules. Table D-2 Messages related to 10102/x/x analog input modules
10102/x/x modules
"ANALOG INPUT SENSOR BREAK ALARM" Reason 1. An analog input value exceeded its specified range. Use the "Loop Status" option of FSC Navigator to determine the tag number. These analog input values are specified in the "System Configuration" option of FSC Navigator. Possible solution 1. Use the "I/O Signal Status" option of FSC Navigator to check the analog input value. If it is within the specified range, activate the FSC Reset key switch. 2. If the alarm message is generated frequently, use the "System Configuration" option of FSC Navigator to check the analog input setting. Please note that if these settings are modified, the new application should be reloaded into the FSC system. 3. If the problem persists, it might be advisable to exchange the field device.
"INPUT COMPARE ERROR" Reason 1. A discrepancy was detected between the analog inputs from Central Part 1 and Central Part 2. Possible solution 1. Check the input for fast transients. An FSC system reset is required to clear the message. 2. If the alarm message is generated frequently, it is advisable to exchange both analog input modules.
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D.4
Analog input module 10105/2/1

Table D-3 below shows the most common alarm/error messages related to the 10105/2/1 analog input module. Table D-3 Messages related to 10105/2/1 analog input module
10105/2/1 module
"ANALOG INPUT SENSOR BREAK ALARM" Reason 1. An analog input value exceeded its specified range. Use the "Loop Status" option of FSC Navigator to determine the tag number. These analog input values are specified in the "System Configuration" option of FSC Navigator. Possible solution 1. Use the "I/O Signal Status" option of FSC Navigator to check the analog input value. If it is within the specified range, activate the FSC Reset key switch. 2. If the alarm message is generated frequently, use the "System Configuration" option of FSC Navigator to check the analog input settings. Please note that if these settings are modified, the new application should be reloaded into the FSC system. 3. If the problem persists, it might be advisable to exchange the field device.
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D.5
Analog output module 10205/2/1

Table D-4 below shows the most common alarm/error messages related to the 10205/2/1 analog output module. Table D-4 Messages related to 10205/2/1 analog output module
10205/2/1 module
"ANALOG OUTPUT SCALING ERROR" Reason 1. The engineering value calculated in the FLDs forced the output of the analog module to go below 0 mA or over 20 mA. This has caused the FSC system to stop. Possible solution Check the FLDs and modify them in such a way that the analog output value can never exceed its minimum and maximum values.
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D.6
Communication errors with the FSC user station

Table D-5 below shows a number of errors that are reported if communication between the FSC system and the user station cannot be established. Table D-5 No communication with the FSC system
Communication errors
"CHECK CONNECTION WITH FSC SYSTEM" Reason 1. 2. 3. 4. 5. An incorrect on-line communication port has been selected. The communication cable is not connected (correctly). The incorrect application has been selected. EPROMs have been inserted incorrectly on a Central Part module. Communication modules have not been correctly placed in the Central Part. You are attempting to communicate with a Central Part that has stopped. A communication module has not been correctly added. Possible solution Use FSC Navigator (On-Line / Communication Port) to change the communication port. Check whether the communication cable is connected to the FSC user station and to the correct FSC system. Use FSC Navigator (File / Open Project) to open the correct application. Check the placement of the EPROMs on the Central Part modules. Look for bent pins on the EPROMs. Verify the placement of the communication modules against the rack layout. Replace the communication cable to the Central Part which is operational. Verify the placement of the communication modules against the rack layout, and check whether the jumper at the rear of the system bus has been removed.
6. 7.
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D.7
Output short circuit

Table D-6 shows the actions to be taken if an output short circuit is reported by the FSC system. Table D-6 Output short circuit
Output short circuit
"OUTPUT SHORT CIRCUIT" Reason 1. The FSC system has detected an short circuit output. Possible solution Use the on-line environment of FSC Navigator to check whether the short circuit has been resolved. If not, the short circuit needs to be solved. After resolving the short circuit, an FSC system reset is required.
229
D.8
Download not successful

Table D-7 shows the most common errors when downloading was not successful. Table D-7 Download not successful
Download not successful
"DOWNLOAD NOT SUCCESSFUL" Reason 1. There is bad communication with FSC system via the FSC-FSC communication link. The RAM size has changed but the hardware has not been modified. Possible solution Retry, or, if possible, try to load directly into the FSC system instead of via the FSC-FSC link. Check the translation log file for the correct size of the RAM chips.
2.
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D.9
Process trip during an on-line modification

Table D-8 shows some possible causes if a process trip occurs during an on-line modification. Table D-8 Process trip
Process trip during OLM
PROCESS TRIP DURING AN ON-LINE MODIFICATION Reason 1. A sheet reference to a lower sheet number has been added (loopback). Due to the processing order of the FLD sheets, this lower on-sheet reference will be "0" during the first application cycle. An output to an "AND" function was set to low due to the fact that one input was missing. This was caused by a new input to this "AND" function. Possible solution Check whether any loopbacks of sheet references have been made. If so, update the FLD to prevent logic trips in the future.
2.
Check the FLDs. If this situation can occur again, prevent this by adding logics.
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D.10
Calculation errors
Table D-9 shows some possible causes if a calculation error is reported. Table D-9 Calculation errors
Calculation errors
"CALCULATION OVERFLOW" Reason 1. The output of a conversion block exceeded the values of the output signal type. Due to this the FSC system stopped. Possible solution Check the FLDs for conversion blocks. Add logic to the conversion blocks which will prevent a calculation overflow.
"DIVIDE BY 0" Reason 1. A division by 0 was attempted. This has caused the FSC system to stop. Possible solution Check the FLDs for division functions. Add logics in order to ensure that the denominator will never be 0.
"ILLEGAL ARGUMENT, E.G. SQUARE ROOT OF 1" Reason 1. A square-root function was performed on a negative value. This has caused the FSC system to stop. Possible solution Check the FLDs for square-root functions. Add logics to the square-root function in order to ensure that the value which the square root function will be performed on, will never be a negative number.
"ILLEGAL COUNTER VALUE (0..8191)" Reason 1. The input value to a counter has exceeded its range. This has caused the FSC system to stop. Possible solution Check the FLDs for counters. Add logics to the counter in order to ensure that the counter input will never exceed the maximum defined counter values.
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Table D-9 Calculation errors (continued)

"ILLEGAL TIMER VALUE (0..2047)" Reason 1. The value written to a timer variable goes below 0 or over 2047. This has caused the FSC system to stop. Possible solution Check the FLDs for timers. Add logics to the timer in order to ensure that the timer input will never exceed the maximum defined timer values.
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Appendix E Checklists
E.1
Section
Section overview
This appendix provides a number of checklists which can be used during preventive maintenance on an FSC cabinet.
Topic See page
Subsection E.1 E.2 E.3 E.4
Section overview........................................................................................... 235 Preventive maintenance overview................................................................ 236 Checklist for three-monthly maintenance ..................................................... 238 Checklist for maintenance during power-down............................................. 241
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E.2
Preventive maintenance overview

Preventive maintenance is necessary to prevent faults in the FSC cabinet. It is concentrated on the most sensitive elements in the FSC cabinet. The preventive maintenance that should be carried out can be split into two major components: Three-monthly preventive maintenance (for checklist see subsection E.3), and Preventive maintenance during every power-down (for checklist see subsection E.4). For details on the items to be checked during preventive maintenance refer to Section 7 of this Service Manual.
Preventive maintenance
Checklists
The checklists contained in subsections E.3 and E.4 allow you to keep a record and retrieve information if any problems should arise. The checklists consist of five sections: General information, FSC configuration items, FSC system information, Items to be checked during preventive maintenance, and Acceptance of checklist.
General information
This section provides general information on the customer, plant and FSC cabinet which preventive maintenance is performed on. This section provides information on software versions, application versions, power-on mode, etc. This information can be retrieved using the FSC user station (with FSC Navigator running on it). For details on how to retrieve this information refer to Section 7 of this Service Manual. This section provides information on Central Part voltages and temperature sensors in the Central Part. For details on how to retrieve this information refer to Section 7 of this Service Manual.
FSC configuration items
FSC system information
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Appendix E: Checklists
Items to be checked
This section provides information on which items are to be checked during the preventive maintenance. For details refer to Section 7 of this Service Manual. This section contains general conclusions about the state of the FSC cabinet as identified during the maintenance performed. After completion of the checks, the customer representative and the Honeywell SMS representative both sign the completed checklist.
Conclusion / comments Acceptance of checklist
237
E.3
Checklist for three-monthly maintenance

Table E-1 Three-monthly maintenance checklist
General Information
Customer: Plant name: Customer representative: Customer reference number: Honeywell representative: Honeywell reference number: Date: FSC cabinet number: FSC application name:
FSC Configuration Items

FSC software version: Memory type: EPROM / RAM / FLASH Cold / Warm start Yes / No Application version: EPROM size CPU: RAM size CPU: Power-on mode: On-line modification: EPROM size COM: Minimum execution time: Maximum execution time: 512 Kb / 1 / 2 / 4 Mb 512 Kb / 1 / 4 Mb 512 Kb / 1 / 4 Mb ms ms
FSC System Information

Central Part 1 Battery voltage S-Bus: Battery voltage DBM: Supply voltage: Temperature sensor 1: Temperature sensor 2: Vdc Vdc Vdc C/F/K C/F/K Battery voltage S-Bus: Battery voltage DBM: Supply voltage: Temperature sensor 1: Temperature sensor 2: Central Part 2 Vdc Vdc Vdc C/F/K C/F/K
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Table E-1 Three-monthly maintenance checklist (continued)
Items To Be Checked
Action Item: A-1: Check the voltages to the Central Parts. A-2: Check the temperatures in the Central Parts. A-3: Check for obstruction of air flow. A-4: Check correct operation of fans. A-5: Check for earth faults (if earth leak detection is available). A-6: Check loop status of signals. A-7: Check forced status of signals. A-8: Check for paint damage. Checked OK: Comments/Notes: Action By:
A-9: Check availability of spare parts. A-10: Check the system diagnostics. A-11: Check the backup of the FSC application files.
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Table E-1 Three-monthly maintenance checklist (continued)
Conclusion / Comments
Item: Conclusion / Comments Action By:
Name of customer representative: Signature: Date:
Name of Honeywell representative: Signature: Date:
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E.4
Checklist for maintenance during power-down

Table E-2 Power-down maintenance checklist
General Information
Customer: Plant name: Customer representative: Customer reference number: Honeywell representative: Honeywell reference number: Date: FSC cabinet number: FSC application name:
FSC Configuration Items

FSC software version: Memory type: EPROM / RAM / FLASH Cold / Warm start Yes / No Application version: EPROM size CPU: RAM size CPU: Power-on mode: On-line modification: EPROM size COM: Minimum execution time: Maximum execution time: 512 Kb / 1 / 2 / 4 Mb 512 Kb / 1 / 4 Mb 512 Kb / 1 / 4 Mb ms ms
FSC System Information

Central Part 1 Battery voltage S-Bus: Battery voltage DBM: Supply voltage: Temperature sensor 1: Temperature sensor 2: Vdc Vdc Vdc C/F/K C/F/K Battery voltage S-Bus: Battery voltage DBM: Supply voltage: Temperature sensor 1: Temperature sensor 2: Central Part 2 Vdc Vdc Vdc C/F/K C/F/K
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Table E-2 Power-down maintenance checklist (continued)
Items To Be Checked
Action Item: B-1: Check the voltages to the Central Parts. B-2: Check the temperatures in the Central Parts. B-3: Check for obstruction of air flow. B-4: Check correct operation of fans. B-5: Check for earth faults (if earth leak detection is available). B-6: Check loop status of signals. B-7: Check forced status of signals. B-8: Check for paint damage. Checked OK: Comments/Notes: Action By:
B-9: Check availability of spare parts. B-10: Check the system diagnostics. B-11: Check the backup of the FSC application files. B-12: Check externally supplied DC voltages. (List feeders with voltage levels.)
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Items To Be Checked
Action Item: B-13: Check DC voltages generated by PSUs in FSC cabinet. (List PSUs with voltage levels.) B-14: Check fuses in power distribution wiring. B-15: Check all AC voltages. (List feeders with voltage levels.) B-16: Check correct operation of all PSUs. B-17: Check fans for dust concentration. B-18: Replace all dust filters. B-19: Check the fasteners on the power distribution units. B-20: Check all cable clamps. Checked OK: Comments/Notes: Action By:
B-21: Check all shield connections. B-22: Check all earth/ground connections. B-23: Test all hardware I/O. B-24: Test all communication links with external devices.
243
Conclusion / Comments
Item: Conclusion / Comments Action By:
Name of customer representative: Signature: Date:
Name of Honeywell representative: Signature: Date:
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Appendix F Using Ferrites

F.1
Section
Section overview
This appendix provides information on the ferrites to be used for the AC and DC power/feeder cables. The ferrites only need to be added if they are not already installed in the FSC cabinet.
Topic See page
Subsection F.1 F.2 F.3 F.4
Section overview........................................................................................... 245 Using ferrites................................................................................................. 246 Ferrites on AC power/feeder cables ............................................................. 250 Ferrites on DC power/feeder cables............................................................. 251
Service Manual Appendix F: Using Ferrites
245
F.2
Using ferrites
Ferrites are used to filter out any electromagnetic interference (EMI) from the power/feeder cables. The ferrites should preferably be of make Wrth or Kitagawa, but equivalent ferrites may also be used. Table F-1 lists the recommended Wrth or Kitagawa ferrites with their characteristics. If ferrites other than Wrth or Kitagawa are used, their impedance specifications should at least equal (or exceed) the values given in Table F-1. Table F-1 Wrth and Kitagawa ferrites and their characteristics
Use of ferrites on cables
HSMS Wrth part no. part no.
Kitagawa part no.
Type Impedance at Impedance at Max. cable (see Figure F-1) 25 MHz (Ohm) 100 MHz (Ohm) diameter 1 pass 2 wind. 1 pass 2 wind. mm in 0.62 1.04 0.20 0.24 0.49 0.31 0.35 0.43
4242011 742 7134 TRCN 28-16-20 4242012 742 7135 TRCN 40-27-15 4242013 742 7114 4242019 742 7111 4242014 742 7122 4242015 742 7143 SFC-4 SFC-5 SFC-10 TFC-16-8-16
A A B* B B C C C
79 48 101 181 155 81 55 81
324 197 411 773 650 311 202 314
160 98 144 253 273 145 98 141
683 382 534 682 744 604 421 555
15.8 26.5 5 6 12.5 8.0 9.0 11.0
4242016 742 7140 TFC-20-10-10 4242017 742 7144 TFC-23-11-14
* This type of ferrite has the shape of an octagonal cylinder.
Figure F-1 Ferrite types
Service Manual
246
Appendix F: Using Ferrites
Ferrite usage
Ferrites can be used in three ways: Single ferrite with single pass (see Figure F-2, left). This is the 'standard' method, which will do for many situations. Multiple ferrites in series with single pass (see Figure F-2, middle). This method can be used as an alternative to the 'standard' method if cable dimensions prohibit the use of a single ferrite to achieve the required impedance. The total impedance will be the sum of the impedance of the individual ferrites. Thus, the total impedance at 25 MHz of two Wrth ferrites, type 742 7134, in series is 158 Ohm (2 times 79 Ohm) (see Table F-1). Single ferrite with double cable winding (see Figure F-2, right). This method can also be used as an alternative to the 'standard' method if cable dimensions prohibit the use of one single-pass ferrite to achieve the required impedance. With this method, the ferrite's total impedance increases by much more than a factor two compared to the 'standard' method. For example, the total impedance at 25 MHz of one Wrth ferrite, type 742 7134, with two cable windings is 324 Ohm (see Table F-1).
1 ferrite single pass

(1sp)
2 ferrites single pass

(2sp)
1 ferrite double winding

(1dw)
Figure F-2 Ferrite layout Note: After the ferrites have been installed, they must be closed completely and tightly. If the ferrite's core is not fully closed, its effect is minimal. You may want to use a tie wrap around the ferrite to ensure that it remains firmly closed.
247
Example:
Consider a situation in which the ferrite impedance of power supply cables must be at least 155 Ohm at 25 MHz and 273 Ohm at 100 MHz (see Table F-1). The 'standard' ferrite to be used is Wrth type 742 7122 (or its Kitagawa counterpart), but if the cable diameter exceeds 12.5 mm (0.49 in), there are alternatives. The table below lists the various options, with the 'alternative' ferrites italicized. Table F-2 Ferrite selection (example)
Wrth part number
Impedance
No. of ferrites req. with single pass (with imp. at 25/100 MHz)
No. of ferrites req. with 2 windings (with imp. at 25/100 MHz)
at 25 MHz 742 7122 742 7134 742 7135 155 79 48
at 100 MHz 273 160 98 1 (155 / 273) 2 in series (158 / 320) 4 in series (192 / 392) 1 (324 / 683) 1 (197 / 382)
Service Manual
248
Ferrite selection table
Table F-3 below lists the types of ferrites that should be used for power supply cables. A number of alternatives are provided, which can be used if the 'standard' is not an option due to cable size limitations. The 'alternative' ferrites are printed in italics. Subsections F.3 and F.4 contain illustrations that show how the ferrites should be installed. Table F-3 Ferrite selection table
Cable types
Req. impedance 25 MHz 100 MHz
Ferrite(s) used*
Layout**
Remark
Power cables: 24, 48, 60, 110, 220 Vdc or 115, 230 Vac 155 273 Wrth 742 7122 Wrth 742 7134 Wrth 742 7134 Wrth 742 7135 Wrth 742 7135 Wrth 742 7144 1sp 2sp 1dw 4sp 1dw 2sp see Figure F-3 and Figure F-4
Notes: * 'Alternative' ferrites to the 'standard' ferrite are printed in italics. These can be used if the 'standard' ferrite is not an option due to excessive cable size. ** 1sp = single ferrite, single pass 1dw = single ferrite, double winding 2sp = two ferrites in series, single pass 4sp = four ferrites in series, single pass 2spdw = two ferrites in series, one with single pass and one with double winding
249
F.3
Ferrites on AC power/feeder cables

Ferrites on AC power/feeder cables should be installed as shown in Figure F-4. The ferrites should be placed as close as possible to the incoming power/feeder fuse terminals and/or main circuit breaker.
Ferrites on AC power/feeder cables
Ferrite 742 7112
Ferrite 742 7112
Fuse terminals
Main circuit breaker
Figure F-3 Ferrites on AC power/feeder cables
Service Manual
250
F.4
Ferrites on DC power/feeder cables

Ferrites on DC power/feeder cables should be installed as shown in Figure F-4.
Ferrites on DC power/feeder cables
Ferrite 742 7112
Ferrite 742 7112
10306/./.
10306/./.
Figure F-4 Ferrites on DC power/feeder cables
251
Service Manual
252
Appendix G Repair Handling and Ordering of Emergency Spare Parts

G.1 Section overview
This appendix provides information on repair handling and ordering of emergency spare parts. It covers the following topics:
Topic See page
Section
Subsection G.1 G.2 G.3 G.4
Section overview........................................................................................... 253 Terminology .................................................................................................. 254 Handling of defective products/parts ............................................................ 255 Ordering of emergency replacements .......................................................... 257
Service Manual Appendix G: Repair Handling and Ordering of Emergency Spare Parts
253
G.2 Terminology
Terminology
Products
The following terminology is important: Products are defined as hardware and/or software designed, manufactured and sold by Honeywell Safety Management Systems (HSMS). Parts are defined as single components from which products are manufactured. Defects are defined as a non-functionality in a product and/or part Repeatable defect is defined as a non-functionality of a product and/or part which finds its origin in the design and/or manufacturing specification. Emergency replacements are products and/or parts required for replacement of defective products and/or parts during the process of a Factory Acceptance Test (FAT) in Honeywell premises and field defects which need emergency exchange. The quantities for emergency replacements are typically small and parts may NOT be used for expansion/modification purposes!
Parts
Defects Repeatable defect
Emergency replacements
Service Manual
254
Appendix G: Repair Handling and Ordering of Emergency Spare Parts
G.3 Handling of defective products/parts

Handling defective products/parts Returning goods Identification This section describes how defective products/parts are handled by HSMS. Defective products/parts can be returned to HSMS for repair. HSMS is the only repair center for the HSMS product/part within the Honeywell organization. The defective product/part shall be clearly identified with: HSMS model number, HSMS serial number, Description of the defect, Shipping address, and Contact person. The product/part shall be clearly labeled stating that it is a defective item. Analysis HSMS will analyze the returned product/part. Upon receipt HSMS will analyze the product/part to verify whether: It is under warranty, It is defective, and It can be repaired. Repair The product/part will be repaired if it is economically justifiable. The defective part will be repaired depending on the HSMS cost estimate analysis. If the cost are considered too high for repairing, the sender will be notified. If cost are too high, the defective part will only be returned to sender upon specific request and at the cost of the sender.
255
Invoices
HSMS will invoice the sender if the warranty period for the part has elapsed: For the amount of the repair cost (these costs will never exceed the costs for a new module), and The shipment costs.
Repair cost estimate Repaired product/part return
Before a part is actually sent in for repair, a repair cost estimate may be requested from HSMS. After a part has been repaired, it will be returned to the sender address unless there are specific shipping instruction to send it elsewhere. If the delivery address differs from the invoice address, a pro-forma invoice will be part of the delivery documents for custom clearance purposes. A repair report will be a standard component of the shipment. All deliveries are ex works HSMS. Upon receipt of a defective part, a receipt notification will be issued to the sender which includes an estimated time to repair. The normal repair cycle for FSC parts is four weeks after receipt at HSMS. The time to repair for non-FSC parts/equipment depends on the repair cycles of their respective suppliers. Emergency replacements can be ordered using the procedure described in subsection G.4.
Time to repair
Emergency replacements
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G.4 Ordering of emergency replacements

Ordering emergency replacements Requests
This section describes how the ordering of emergency replacements is handled by HSMS. Requests for emergency replacements must be communicated with HSMS. Requests for emergency replacements must be submitted to HSMS by means of a fax message which clearly indicates "EMERGENCY REPLACEMENT REQUEST". As a minimum, the fax must state the following: HSMS model number, Description, Quantity, Originator, Shipping address, Warranty replacement status (yes/no), and If it is a warranty replacement, model and serial number of the defective part.
Fax
Shipment and documents
The shipment of the emergency replacement will be accompanied by a pro-forma invoice and a bill of lading stating that it is a repair replacement for custom clearance. All deliveries are ex works HSMS. An invoice will be sent to the requester based on the project price for the part(s) requested, plus the shipping cost. After receipt of the defective item(s) at HSMS, a credit note of 25% of the price will be submitted, providing the defective item can be repaired.
Invoice
Credit note
257
Beyond repair
If it turns out that a returned product/part cannot be repaired, the requester will be informed and no credit note will be submitted. HSMS will check whether the returned item is still under warranty. If it is, a credit note of 100% of the price will be submitted.
Warranty
Return of defective product/part
The defective product/part must be returned to HSMS.
Service Manual
258
READER COMMENTS
Honeywell Safety Management Systems welcomes your comments and suggestions to improve future editions of this and other documents. You can communicate your thoughts to us by fax or mail using this form, or by sending an e-mail message. We would like to acknowledge your comments please include your complete name, address and telephone number.
BY FAX:
Use this form and fax to us at +31 (0)73-6219125 (attn. PM dept.)
BY E-MAIL: Send an e-mail message to sms-info@honeywell.com BY MAIL:

Use this form and mail to us at: Honeywell Safety Management Systems B.V. Attn. Marketing Department P.O. Box 116 5201 AC 's-Hertogenbosch The Netherlands
Title of Document:
Fail Safe Control Service Manual Revision 03 FS99-504
Issue Date: 03/2000
Document Number:
Writer: HSMS Product Marketing
COMMENTS:
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Fail Safe Control

Copyright, Notices and Trademarks

Section 2 Installation Guide

Section 3 Connection of External Cables

FSC Service Manual Table of Contents

TABLE OF CONTENTS (continued)

Section 4 Power-Up of the FSC Cabinet

Section 5 Site Acceptance Test

Section 6 General Maintenance Considerations

FSC Service Manual

TABLE OF CONTENTS (continued)

Section 8 Troubleshooting and Fault-Finding

FSC Service Manual Table of Contents

TABLE OF CONTENTS (continued)

Section 10 Training Courses

FSC Service Manual

TABLE OF CONTENTS (continued)

Appendix A Plinth Layouts

Appendix B Stopping / Powering Down the FSC System

FSC Service Manual Table of Contents

TABLE OF CONTENTS (continued)

Appendix D Alarm/Error Messages and Solutions

Appendix F Using Ferrites

FSC Service Manual

TABLE OF CONTENTS (continued)

FSC Service Manual Table of Contents

FSC Service Manual

FSC Service Manual Table of Contents

FSC Service Manual Table of Contents

FSC Service Manual

FSC Service Manual Table of Contents

FSC Service Manual

Subsection 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Scope of this document

Service Manual Section 1: Introduction

Start of an FSC system

Power-up of an FSC cabinet

Service Manual Section 1: Introduction

Precautions when working on FSC cabinets

Keep the doors closed

Electrostatic discharge (ESD)

Figure 1-1 ESD wrist-strap connected to ESD bonding point

Service Manual Section 1: Introduction

Service Manual Section 1: Introduction

FSC user documentation

Service Manual Section 1: Introduction

Left blank intentionally.

Section 2 Installation Guide

Honeywell SMS representative

Service Manual Section 2: Installation Guide

Mobile lifter / fork lift

Section 2: Installation Guide

Service Manual Section 2: Installation Guide

Section 2: Installation Guide

Shock: Other items

Service Manual Section 2: Installation Guide

FSC general cabinet layout

Maximum number of cabinets

Section 2: Installation Guide

Front / rear access

Bolting down cabinets

Service Manual Section 2: Installation Guide

Section 2: Installation Guide