MAX DNA DPU - A1

Model PDP DPU
Installation, Preparation
and Adjustment
277573 Rev. A1
Refer to this publication for complete and accurate information that helps you better operate and service Metso
Automation MAX Controls equipment. Your comments and suggestions are welcome.
Metso Automation MAX Controls
1180 Church Road
Lansdale, PA 19446
Attention: Manager, Technical Publications
Copyright 1999-2001 by Metso Automation MAX Controls Inc.

Printed in the United States of America
All rights reserved
Metso Automation MAX Controls 277573
Contents
PREFACE ........................................................................................................................... III
CHAPTER 1 ...................................................................................................................... 1-1
Introduction................................................................................................................................................................. 1-1
Distributed Processing Unit Functionality ................................................................................................................ 1-1
Distributed Processing Unit Hardware .............................................................................................................. 1-1
Distributed Processing Unit Specifications ....................................................................................................... 1-2
Mounting the DPU ................................................................................................................................................ 1-2
Positioning the DPU.......................................................................................................................................... 1-2
Mounting Procedures ........................................................................................................................................ 1-3
Wiring the DPU .................................................................................................................................................... 1-3
CHAPTER 2 ...................................................................................................................... 2-1

DPU Front Panel ......................................................................................................................................................... 2-1
Overview................................................................................................................................................................... 2-1
Mode Select DIP Switch Settings.......................................................................................................................... 2-1
Data Highway Area ............................................................................................................................................... 2-2
Using Rotary Switches to Set Station Address .................................................................................................. 2-2
Two LED Displays............................................................................................................................................ 2-3
IOM Load.......................................................................................................................................................... 2-3
Status Section (LEDs) ........................................................................................................................................... 2-4
DPU Hardware Status LEDs ............................................................................................................................. 2-4
Serial I/O and DPU Status Section.................................................................................................................... 2-4
Backup Status LEDs.......................................................................................................................................... 2-5
Reset Button.......................................................................................................................................................... 2-6
Backup Link .......................................................................................................................................................... 2-6
CPU Load.............................................................................................................................................................. 2-6
Takeover Button.................................................................................................................................................... 2-6
Backup DIP Switch Settings ................................................................................................................................. 2-6
DPU Keyswitch..................................................................................................................................................... 2-7
CHAPTER 3 ...................................................................................................................... 3-1

Input/Output Connections.......................................................................................................................................... 3-1
Data Highway............................................................................................................................................................ 3-1
ACSII Ports ....................................................................................................................................................... 3-1
Model PDP DPU Installation, Preparation and Adjustment

CHAPTER 4.......................................................................................................................4-1
DPU Battery and Fuse Maintenance ......................................................................................................................... 4-1
Battery Types ............................................................................................................................................................ 4-1
Replacing the NiCd Battery Pack (Battery #2)...................................................................................................... 4-1
Replacing the Lithium Battery (Battery #1) .......................................................................................................... 4-2
Replacing DPU Fuses............................................................................................................................................ 4-3
CHAPTER 5.......................................................................................................................5-1
Backing up the DPU.................................................................................................................................................... 5-1
Overview ................................................................................................................................................................... 5-1
Automatic Failover/Manual Takeover............................................................................................................... 5-1
Automatic Failover............................................................................................................................................ 5-1
Manual Takeover............................................................................................................................................... 5-1
Cable Disconnect............................................................................................................................................... 5-2
CHAPTER 6.......................................................................................................................6-1
Starting the DPU ......................................................................................................................................................... 6-1
Startup States............................................................................................................................................................. 6-1
Demanding a Cold Startup .................................................................................................................................... 6-2
Starting a Standalone DPU.................................................................................................................................... 6-2
Starting a Backup Pair of DPUs ............................................................................................................................ 6-3
Replacing a DPU in a Backup Pair........................................................................................................................ 6-5
CHAPTER 7......................................................................................................................7-1
Using Interaction Pages ............................................................................................................................................. 7-1
Accessing Displays.................................................................................................................................................... 7-1
Using Interaction Page 9 Display with a Workstation........................................................................................... 7-1
Startup ............................................................................................................................................................... 7-1
Backup Option................................................................................................................................................... 7-1
Digital Input Filter Time Field .......................................................................................................................... 7-2
Serial Ports Field ............................................................................................................................................... 7-2
Lockout and Log Options Field......................................................................................................................... 7-2
Using Interaction Page 9 Display with an Operator Station .................................................................................. 7-2
Startup ............................................................................................................................................................... 7-4
Backup Option Field ......................................................................................................................................... 7-4
Stat Page Field................................................................................................................................................... 7-4
DIO Inventory Field .......................................................................................................................................... 7-4
Digital Input Filter Time Field .......................................................................................................................... 7-5
Analog Input Inventory Field ............................................................................................................................ 7-5
Redundant I/O Address Ranges Field................................................................................................................ 7-5
Lockout and Log Options Field......................................................................................................................... 7-5
Serial Ports Field ............................................................................................................................................... 7-5
Interaction Page 10................................................................................................................................................ 7-6
Event Queue Pointer Information...................................................................................................................... 7-7
Interaction Page 13.............................................................................................................................................. 7-10
Contents
CHAPTER 8 ..................................................................................................................... 8-1
Alarms and Diagnostics .............................................................................................................................................. 8-1
Annunciation of Alarms ............................................................................................................................................ 8-1
Front Panel Numeric LEDs ............................................................................................................................... 8-1
Preface
The Distributed Processing Unit described in this publication consists of two

models, the Model PDP001 Series and the Model PDP100 Series. From a
hardware perspective, the two models are virtually identical. At the software
level, however, the two models contain different firmware. The Version 7.1
Firmware makes the Model PDP100 Series compatible with the IEC 1131-3
toolset. The Model PDP001 Series supports Metso Automation MAX
Controls EXtended Control Engineering Language (ExCEL), a Metso
Automation MAX Controls programming language, and ladder logic.
In addition to DPU front panel controls, to a limited extent you may control
a DPU from the maxSTATION running maxVUE Runtime software.
maxVUE Runtime also lets you monitor DPU status, DPU-related alarms,
and access DPU Interaction Pages, containing data and system statistics
stored in the DPU. Interaction Pages are described in Chapter 3. For
maxVUE Runtime information, refer to Publication 277557, MaxSTATION
Operator' s Guide. You may reload a DPU's configuration from the
maxSTATION running maxTOOLS software. Refer to the maxTOOLS
online help supplied with the package for configuration installation
instructions.
Chapter 1
Introduction
Distributed Processing Unit Functionality
The Model PDP Distributed Processing Unit (DPU) performs primary data
acquisition, control, and data processing functions for the maxDNA
Distributed Control System. The DPU is a self-contained microprocessorbased, rack-mounted unit, which occupies a single slot in a Remote
Processing Unit cabinet. It is designed to operate with user-defined
combinations of maxDNA Model IOP Input/Output Modules, and to
communicate with other devices, such as Programmable Logic Controllers
and Remote Terminal Units.
As a station on the DPU Bus, the DPU scans and processes information for
use by other devices in the maxDNA system. Each DPU performs:
Comprehensive alarming and calculations.
Logging of Sequence of Events (SOE) data.
Acquisition of trend information.
Continuous scanning of Model IOP I/O modules.
Execution of predefined Control and Data Blocks for process control and
data acquisition.
Execution of user written programs using IEC1131-3 Toolset or Metso
Automation MAX Controls EXtended Control Engineering Language
(ExCEL).
Ladder logic processing.
Assurance of secure link-level data highway communications.
Distributed Processing Unit Hardware

A DPU consists of three circuit cards installed in a rack-mounted chassis.
The right front chassis panel contains two clockwise and counter-clockwise
connectors, two serial ports, 10 terminal blocks, and the DPU keylock.

The processor cards mounted behind the gray and white front panel consist
of the motherboard, Data Highway Card, and the Control Processor Card.
The Data Highway Card and Control Processor Card are mounted as
daughter cards on the motherboard.
Except for the Control Processor Card, the front edge of each processor card
features switches, indicator lamps, and rotary dials that are visible and
accessible from the DPU front panel.
Distributed Processing Unit Specifications

Operating temperature range
0 to 60 degrees C
Storage temperature range
(-)25 to 70 degrees C
Relative humidity range
5 to 90% noncondensing
Power requirements
24 Vdc 4 Vdc, 1.2 amps
Mounting the DPU

The Model PDP Distributed Processing Unit (DPU) is mounted on the
Input/Output (I/O) backplane with Model IOP Input/Output modules.
Positioning the DPU

The DPU must be mounted in the right most position of the Model IOP rack
since the DPU is wider than the I/O cards and requires good air flow. In a
six-wide I/O rack, the mounting bracket to the left of the DPU must be
removed since the DPU requires an I/O panel.
When using a second DPU for backup, it must be mounted vertically
adjacent to the primary DPU.
When the DPU is installed in the right most slot, the DPU cover extends
over the J3 and J4 connectors on the back panel. The standard daisy-chain
cable (064353) is low profile, however, and will not cause any interference.
Any cables higher than 1 inch above the surface of the backplane, and any
terminators, will interfere with the cover. Some older cables, in particular,
will interfere with the DPU cover. It may be possible to move the terminator
to the other end of the daisy-chain or to rearrange the order of the
daisy-chain cables to eliminate the interference.
If this is not possible, a cable adapter is available (Metso Automation MAX
Controls Part Number 081580). This adapter has a metal bracket which
mounts to the power strut and a 12-inch connecting cable plugs into J3 or J4
on the back panel. It is a male-female adapter so that the original cable or
1-2
Introduction
terminator can be plugged directly into the adapter out of the way of
interference with the DPU.
The DPU is designed to allow installation and removal with the +24 V dc
power supply turned on.
Mounting Procedures
Before mounting any hardware, refer to the cabling and field wiring sections
of Publication 277563, Model IOP Input/Output System Installation and Preparation, for information also pertinent to mounting.
To install the DPU in the rack, refer to Chapter 6.
Wiring the DPU

With the exception of the 10 point terminal block on the front panel of the
DPU chassis, no hard wiring is required. All connections between the DPU
module and the DPU chassis are made upon installation into the I/O rack.
Use maxTOOLS to create input designations for each DPU during
configuration.
Ten terminal board connectors, with #6 screws, are positioned at the lower
left side of the DPU chassis. Pin-outs are as follows:
Table 1-1. Ten Point Terminal Block
PIN No.
1-6
Purpose
Reserved
Open
8, 9
DPU offline contact (photovoltaic relay, opens when the DPU is

offline)
Peak operating voltage = 300V
Maximum load = 60 mA
On resistance = 30 Ohms
Off resistance = 1 mOhms (Contact is closed if DPU is online)
10
Circuit Ground
1-3
Chapter 2
DPU Front Panel
Mode Select
1
0
CW
8
4
2
1
Off
On
CCW
Off
Data Highway
Overview
On
All DPU controls, indicator lamps,

keylock, and switches are located on the
DPU front panel. Refer to Figure 2-1,
DPU Front Panel. Use this front panel to
monitor or control different aspects of
the DPU. This chapter describes and
illustrates individual sections. The
various front panel features are generally
positioned in two vertical panel areas
corresponding to supporting processor
card positions mounted behind the front
panel.
Jabber
Status
Stn No.
IOM
Load
G Active
R Offline
Y Inactive
State
Battery
Power
1
Serial Ports
2
G- Tx
R- Rx
DI
DO
Mode Select DIP Switch Settings
G- Active
R- Error
Prog IO
Distributed Processing Unit
The mode switches, located at the top of

the front panel, are used during DPU
manufacturing and testing. For normal
DPU operation, all four switches should
be set to the left. Setting the B (Blank
database) SW8, 2, 1 to the left, and SW4
to the right during power on or reset
causes the DPU to erase its database and
come up cold. Once the DPU is
operational (DPU on DPU Bus), be sure
to set the mode switches back to the left.
Per IO
Tx
Backup
Rx
Reset
CPU Load
Backup
Link
Takeover
Figure
2-1.
Front Panel
DPU
Sec
Com
Pri
PIO
SIO1
SIO2
Sep
Data Highway Area

The Data Highway Area, (Figure 2-2), located in the upper right area of the
gray front panel, consists of:
Two toggle switches used to intentionally break the CW and/or CCW
highway connections to this DPU to simulate communications loss for
systems testing (e.g., cable break reporting) without actually disconnecting
cables.
Jabberhalt error LED to indicate timeout of excessively long transmissions.
Two rotary switches to provide the station address; refer to next section.
Two LED displays; refer to "Two LED Displays."
There are no internal switches or jumpers to be set during installation.
Figure 2-2. Upper Front Panel Area
2-2
DPU Front Panel

Using Rotary Switches to Set Station Address
Use the two rotary switches to configure a unique DPU highway station
address, a number ranging from 32 and 63; the station number is set in
hexadecimal (hex). The upper switch sets the most significant digit of the
address (e.g., 3 for Station 50). The lower switch sets the least significant
digit for the address (e.g., 2 for Station 50).
Hexadecimal
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
Decimal
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
To convert a two-digit hexadecimal number

to decimal, multiply the first digit by 16 and
add the decimal value of the second digit.
2C hex = 2 * 16 + C
= 32 + 12
= 44
To convert decimal to hexadecimal, divide
the decimal number by 16 until a remainder
of less than 16 is obtained:
50 decimal
= 5016 = 3 (hex)
with 2 (2 hex) remainder
= 32 hex
Two LED Displays

The two seven-segment LED displays report highway status using hex
numbers. During DPU startup, the LEDs display FF. When the DPU
concludes its startup phase, the LEDs alternately display the codes 03, 04,
and 07 to indicate:
(03) query response transfer is in progress
(04) token passing is in progress
(07 the DPU is executing normal background functions
If an error occurs in the DPU, causing it to fail, these LEDs display an error
code. Refer to Chapter 8 for a listing of error codes.
IOM Load
Metso Automation MAX Controls Factory Service use only.
2-3
Status Section (LEDs)

The middle area of the front panel contains 11 tri-colored LEDs (green, red,
and yellow). Refer to Figure 2-3. The LEDs indicate the status of a variety of
tasks, such as I/O bus scanning. Refer to the following tables for a list of
definitions for the color-coded LEDs.
DPU Hardware Status LEDs

The first three LEDs specifically relate to DPU hardware status.
LED
What the Colors Mean
Active
Offline
Inactive
Green = DPU online and active.

Red = DPU offline.
Yellow = DPU online but inactive (backup pair).
Battery
Red = nickel cadmium or lithium battery bad.

Yellow = nickel cadmium battery under test.
Green = both batteries good.
Power
Green = DPU powered.
Figure 2-3. Status LEDs
2-4
DPU Front Panel

Serial I/O and DPU Status Section
LED
Serial port1
Green = serial port 1 transmitting.

Red = serial port 1 receiving.
Serial port2
Green = serial port 2 transmitting.

Red = serial port 2 receiving.
Status Section LED Indicators

DI
Fast Digital Input Scanning:
green =
red =
yellow =
off =
DO
all points good

all points bad
some points good and some points bad
no points executing
Fast Digital Output Scanning:
green =
red =
yellow =
off =
Per IO
all points good

all points bad
no points executing
Periodic Input/Output scanning Analog
Inputs, Control Blocks, Data Blocks
green =
red =
yellow =
off =
Prog IO
all points good

all points bad
no points executing
ExCEL Input/Output Scanning
green =
red =
yellow =
off =
all points good

all points bad
no points executing
Backup Status LEDs

The following two LEDs report backup link status.
LED
RX
TX
green = Receiving data.

green = Transmitting data.
2-5
Reset Button
The Reset pushbutton does not produce a true hard reset; when you press
this button, the DPU receives a false indication of impending +24 Volt
power loss, causing the DPU to save the database into flash memory and
wait for a power down that never occurs. However, a deadman timer
associated with the Control Processor Card will cause a true hard reset after
this routine finishes, after which a cool initialization will occur.
Backup Link
When used with a backup DPU, a cable (Part 081387) runs between this
connector on both DPUs.
When used without a backup DPU, a terminator (Part 081388) must be
installed in this connector.
CPU Load
For Metso Automation MAX Controls Factory Service use only.
Takeover Button
When two DPUs are used in a backup configuration, press the Takeover
button on one of the DPUs to force that DPU to take control, making the
other inactive.
Backup DIP Switch Settings

Use the four-position backup DIP switch to select various DPU backup
configurations. If backup is not configured, the top most switch should be set
to the right and the others to the left. Refer to Chapter 5.
The first position (top) on the DIP switch lets you designate the DPU as
primary or secondary. Primary is to the right.
The second position designates a separate or shared parallel input/output
bus. Common (Shared) is to the left. Separate is to the right.
Note: if you are configuring a mixed I/O system using some shared and some
separate I/O with a Y-Adapter, select Separate.
2-6
DPU Front Panel

The third position designates a separate or shared link connected to serial
port 1. Separate is to the right. Common (Shared) is to the left.
The fourth position designates a separate or shared link connected to serial
port 2. Separate is to the right. Common (Shared) is to the left.
DPU Keyswitch
Use the DPU keyswitch, located at the bottom part of the DPU chassis, to
select one of three operator modes. The DPU can operate with the key in
place or removed; you can remove the key from the switch regardless of key
position.
The keyswitch may be placed in one of the following three positions:
Run
Keyslot horizontal
The DPU executes the functions defined in its point
database. In this mode, you are permitted to reload a DPU
database; however you cannot configure Interaction Page 9.
Offline
Keyslot diagonal, one-quarter turn counterclockwise from

Run.
In this mode, the DPU scans inputs but does not execute
outputs. To service the DPU, you may manually select
offline by turning the keyswitch to this position.
Offline is imposed automatically with the keyswitch in run or
locked position when a fatal diagnostic is detected.
Locked
Keyslot diagonal, one-quarter turn clockwise from Run.

In this mode, the DPU executes the functions defined in its
point database. Reloads and database changes may or may
not be permitted, depending on the DPU configuration as
shown on Interaction Page 9.
2-7
Chapter 3
Input/Output
Connections
Data Highway
The upper left portion of the DPU chassis features two groups of male and
female 9-pin D-type connectors used to connect the clockwise (CW) and
counter-clockwise (CCW) DPU Bus cables. Positions J2 and J3 are for CW
connections, and J4 and J5 are for CCW. For additional information on
Input/Output connections, refer to Publication 277580, DPU Bus Cabling.
ACSII Ports
Directly below the DPU Bus connections are two female 25-pin D-type
connectors (J6 and J7) which serve as ASCII serial ports. Table 3-1 provides
the pin-outs for both ports. These two ASCII ports provide linkage to
programmable logic controllers, remote multiplexers, etc. Connections can
be RS-232, RS-422, or RS-485, chosen without jumpers, with proper
connection to the 25-pin D-Connectors. When you define a DPU via
maxTOOLS, you may configure setup parameters, such as baud rate, parity,
and number of stop bits. You may also enter setup information directly on
Interaction Page 9. Remember, when you add this information, you must
take the DPU offline.
Table 3-1. ASCII Port Pin-outs (usable via ExCEL, Rev. 2)
Pin No.
Purpose
24
2
23
3
4
5
7
1
Transmit Data
Transmit Data
Receive Data
Receive Data
Request-to-Send
Clear-to-Send
Circuit Ground
Chassis Ground
TxD + (RS-422)
TxD - (RS-422), or TxD (RS-232/423)
RxD + (RS-422)
RxD - (RS-422), or RxD (RS-232/423)
RTS (RS-232/423)
CTS (RS-232/423)
Chapter 4
DPU Battery and
Fuse Maintenance
Battery Types
The Model PDP DPU uses two battery types that must be replaced
periodically. A Nickel Cadmium (NiCd) rechargeable battery pack, mounted
on the motherboard, allows the DPU to preserve its database when power
goes down. This battery, tested for one minute every hour, will raise a "battery #2 weak" battery low alarm if it fails.
The DPU Control Processor Card uses a 360 maH Lithium battery to
preserve CMOS settings and time and date. If this battery fails, a "battery #1
weak" battery low alarm will be raised. The battery has a shelf life of 10
years under "no load" conditions. When the DPU is powered, the battery is
electronically disconnected. The Control Processor Card battery will last for
more than two years if no power is applied to the board.
Caution: The DPU contains devices that can be damaged by electrostatic
discharge. It is imperative that the DPU be carried in antistatic protective
bags. Grounded workstations and wrist straps must be used when
adjusting or performing any work on the DPU. If soldering irons are used,
they must also be grounded.
Replacing the NiCd Battery Pack (Battery #2)

Note: when the DPU is shipped or put in storage, always unplug the NiCd
battery pack from the P10 connector.
The DPU NiCd battery pack (Part number 081537) should be replaced at
least every three years. Spare NiCd battery packs have a shelf life of 5 to 7
years.
The battery is located in an accessible compartment on the upper right side
of the DPU. To access the battery, you must remove the DPU from the rack
as described in the following procedure:

To replace the battery:
1.
Important: If the DPU to be serviced is part of a DPU pair, use the

instructions in Chapter 6, "Replacing a DPU in a Backup Pair," to
extract the DPU. If the DPU to be serviced is configured standalone,
place the keyswitch in the offline position and use the following
instructions.
Gently slide the DPU module out of the cabinet rack and set the unit
down on an appropriate work surface, component side up.
2.
Locate the battery compartment on the upper right side.
3.
Remove the battery plug connector from the P10 port.
4.
Remove the failed battery from its holder clips and dispose of it
appropriately.
5.
Slide the new battery pack in between the holder clips and plug the
battery's plug connector into the P10 port.
6.
Install the DPU in the chassis using the appropriate procedure found in
Chapter 6," Starting a Standalone DPU," or "Replacing a DPU in a
Backup Pair."
Replacing the Lithium Battery (Battery #1)

The Lithium battery is mounted on the Control Processor board. Replace the
battery with a 360mAh TLS186 Tadiran battery or equivalent. (Part number
081558).
To replace the battery:
1.
Important: If the DPU to be serviced is part of a DPU pair, use the

instructions in Chapter 6, "Replacing a DPU in a Backup Pair" to
extract the DPU. If the DPU to be serviced is configured standalone,
place the keyswitch in the offline position and use the following
instructions.
Gently slide the DPU module out of the cabinet rack and set the unit
down on an appropriate work surface, component side up.
4-2
2.
Remove the top metal cover.
3.
Locate the battery. It is on the top side of the Control Processor board
near the DB25 connector.
4.
Carefully remove the battery by pulling it straight up. Do not use any
metal tools since they could short the battery leads. Additionally, do
DPU Battery and Fuse Maintenance

not place any pressure on the circuits near the battery.
5.
Install the battery into the same connector from which the old battery
was removed (B1). Make sure that the (+) lead, the center of the
battery, plugs into the end pin of the connector marked with the (+) on
the board. The second lead (-) should go into the fourth pin on
connector B1.
6.
Install the metal cover.
7.
Install the DPU in the chassis using the appropriate procedure found
in Chapter 6," Starting a Standalone DPU," or "Replacing a DPU in a
Backup Pair."
Replacing DPU Fuses

The DPU has two fuses, located on the motherboard, marked F1 and F2.
Both fuses are subminiatures (resemble resistors). Fuse F1, 3A (Part number
014257), is used for external battery power. Fuse 2, 3A (Part number
014257), is used for 24V power. They are both mounted directly to the board
by their leads and plugged into sockets.
To change the fuses, follow the same procedure for changing the lithium
battery, as described in the previous section, locate and replace the fuses.
4-3
Chapter 5
Backing up the DPU
Overview
In a redundant configuration, two DPUs are connected to form a backup pair.
One DPU is designated as the primary unit and the other DPU the secondary
unit. The DPU Bus station address of the secondary station is one number
greater than the address of the primary station.
The installation, preparation, and adjustment procedures included in this
publication apply to both DPUs in a redundant configuration. This chapter
provides information on switches and cabling in a redundant configuration.
Automatic Failover/Manual Takeover

Process control can be transferred automatically (Failover), or you can
manually command takeover. Automatic Failover can only occur from the
primary DPU to the secondary DPU; a secondary DPU will never automatically failover to a primary unless the secondary loses power or is reset.
Automatic Failover
Process control is automatically transferred from the primary DPU to the
secondary DPU when the primary DPU experiences a severe diagnostic
alarm or when communication between primary and secondary DPU is lost.
However, if the secondary DPU is itself experiencing a severe diagnostic
alarm, it will refuse control, unless the primary DPU loses power or is reset.
After the alarm condition in the primary DPU is rectified, acknowledge all
remote alarms, confirm configuration using Interaction Page 9, and press the
takeover button on the front panel of the primary DPU to return control.
Manual Takeover
To manually command either DPU to assume control, press the takeover
button on the front panel of the unit. Manual takeover will occur even if a
severe diagnostic alarm or a fatal alarm condition exists in the DPU whose
button is pressed.

If you manually transfer to primary while the primary has a severe diagnostic
alarm, automatic failover may cause control to transfer back to the secondary
when you release the Takeover button, as described above.
Cable Disconnect
The backup serial link cable (Part number 081387) carries data signals
between the primary and secondary DPUs, as well as a status signal which
determines which DPU is active. If one end of this cable is removed from
either DPU, that unit is rendered inactive.
If a DPU is not part of a backup pair, a terminator (Part number 081388)
must be inserted in place of the cable.
5-2
Chapter 6
Starting the DPU
Startup States
Refer to this chapter to learn how to:
Start a standalone DPU
Start DPUs in a backup pair
Replace a DPU in a backup pair
When a DPU is restarted, it senses the type of initialization being performed
and starts in one of the following two modes:
Cold
A Cold initialization occurs following a power outage if no

configuration information is available from before the outage.
This can occur if no battery power is available when the DPU is
powered down, or if a Cold start is demanded through the front
panel mode switches. Following a Cold start, the DPU will remain
in Offline state until it is manually placed online. Refer to
"Demanding a Cold Startup."
Cool
A Cool initialization occurs if configuration data is available in

flash memory, unless a Cold start is demanded through the front
panel mode switches. Following a Cool start, the DPU will
automatically progress to Online state unless its keyswitch is in
the Offline position.
In both modes, the DPU uses the time and date preserved in its CMOS clock,
then synchronizes with other stations on the DPU Bus. If the CMOS clock is
not valid, the DPU will raise an alarm and remain Offline until it receives
time via the DPU Bus.
When the DPU is reset or the 24 Vdc power to the DPU is interrupted, Event
Queue information is lost, but the internal battery allows the configuration to
be preserved in flash memory. When the DPU restarts, it reloads its
configuration and erases the flash memory to prevent the possibility of later
reloading an out of date configuration.
Demanding a Cold Startup

When a DPU is first placed in service, or when a DPU is moved from one
location to another, it is advisable to clear any previous configuration data
that may remain in its flash memory. To do this, before applying power to
the DPU, set front panel mode switches 1, 2, and 8 to the left, and mode
switch 4 to the right. After the DPU has gone through its startup sequence as
described in "Starting a Standalone DPU," be sure to set mode switch 4 back
to the left to prevent future Cold startups.
Starting a Standalone DPU

Perform the following steps to ensure that a DPU is completely configured
before it is allowed to assume control. It is important that the DPU not be
placed in the Online state until it has been fully configured.
To start a standalone DPU:
6-2
1.
Turn the DPU keylock to the Offline position (fully counter-clockwise).
2.
Insert a terminator (Part number 081388) in the backup link connector.
3.
On the backup DIP switch at the bottom of the DPU, set the top most
switch to the right (primary).
4.
Set front panel mode switches 1, 2, and 8 to the left, and set mode switch
4 to the right to demand a Cold startup, as described in the preceding
section.
5.
Verify that the NiCd battery pack is installed and plugged correctly into
P10 connector on the motherboard. Additionally, verify that protective
connectors (Part number 081389) are installed in the IOM and CPU load
connectors.
6.
Set the proper DPU Bus address in the station number switches.
7.
Position the module into the top and bottom card guides of the chassis.
8.
Carefully slide the module forward, verifying that the connector pins on
the solder side of the module engage the corresponding contact guides on
the chassis assembly.
9.
When the contacts are engaged and resistance is felt, firmly press on the
front panel of the module front plate to make the simultaneous
connections at the front and rear. Apply pressure to the left of the LEDs
to place the force directly in line with the printed circuit card of the
module.
Starting the DPU

10.
Secure module to chassis assembly with the top and bottom lock down
screws on the front of the module.
11.
Before it begins DPU Bus communications, the DPU will initially

display FF as its front panel LEDs, progress through a series of steps
counting down from 0F to 06. Once it begins communicating, a healthy
DPU will display a rapidly flickering number whose value is
predominantly 07.
12.
Return mode switch 4 to the left.
13.
Reload the DPU using maxTOOLS at a maxSTATION

Dump/Reload mode at the Operator Station.
14.
Acknowledge all alarms from the DPU and make sure that they all clear.
15.
Display Interaction Page 9 of the DPU at a maxSTATION. Locate the

Backup? Field and type n for no; locate the Startup? Field and type y
for yes.
16.
Place the keyswitch in the Run or Locked mode.
or the
Starting a Backup Pair of DPUs

When starting a backup pair of DPUs, you must bring the primary DPU up
first and make sure it is running properly before starting the secondary.
Perform the following steps to ensure that an unexpected failover does not
occur during the startup process.
To start DPU backup pairs:
1.
Turn both DPU

counter-clockwise).
keylocks
2.
Set the top most backup DIP switch appropriately for each DPU (to
the right for primary, to the left for secondary).
3.
Set the remaining backup switches (shared/separate I/O) appropriately

as described in Chapter 2,"Backup DIP Switch Settings"; make sure
the corresponding switch positions match in each DPU.
4.
On each DPU, set front panel mode switches 1, 2, and 8 to the left; set
mode switch 4 to the right to demand Cold startups from each unit.
5.
Verify that the NiCd battery pack is installed and plugged correctly
into P10 connector on the motherboard. Additionally, verify that
protective connectors (Part number 081389) are installed in the IOM
to
the
Offline
position
(fully
6-3

and CPU load connectors.
6-4
6.
Set the proper DPU Bus address in the station number switches.
7.
Position each DPU into the top and bottom card guides of each
chassis, but DO NOT push them in far enough to apply power to the
units.
8.
Connect a backup cable (Part number 081387) between the units. Note
that the cable ends are keyed so that they can only be inserted one
way.
9.
For the primary, carefully slide the module forward, verifying that the
connector pins on the solder side of the module engage the
corresponding contact guides on the chassis assembly.
10.
When the contacts are engaged and resistance is felt, firmly press on
the front panel of the module front plate to make the simultaneous
connections at the front and rear. Apply pressure to the left of the
LEDs to place the force directly in line with the printed circuit card of
the module.
11.
12.

counting down from 0F to 06. Once it begins communicating, a
healthy DPU will display a rapidly flickering number whose value is
predominantly 07.
13.
14.
Reload the primary DPU using maxTOOLS at a maxSTATION or the

Dump/Reload mode at an Operator Station.
15.
Acknowledge all alarms from the primary DPU.
16.
Display Interaction Page 9 of the DPU at a maxSTATION or Operator

Station. Locate the Backup? Field and type y for yes; locate the
Startup? Field and type y for yes.
17.
Place the keyswitch of the primary DPU in the Run or Locked mode.
18.
Insert the secondary card using the same steps as the primary.
19.
Make sure the secondary starts up and begins communicating on the

DPU Bus as described above.
20.
Starting the DPU

21.
Reload the secondary DPU using maxTOOLS at a maxSTATION or

the Dump/Reload mode at an Operator Station.
22.
Acknowledge all alarms from the DPU pair and make sure that
secondary alarms are all clear.
23.
Display Interaction Page 9 of the DPU at a maxSTATION or Operator

Station. Locate the Backup? Field and type y for yes; locate the
Startup? Field and type y for yes.
24.
Make sure that the primary DPU is displaying the alarm Backup Link
Timeout to make sure there are no higher priority alarms.
25.
Place the keyswitch of the secondary DPU in the Run or Locked

mode.
26.
Acknowledge all DPU alarms and make sure they all clear.
Replacing a DPU in a Backup Pair

When replacing a DPU in a backup pair, it is necessary to prevent the new
unit from gaining control until it is properly configured and up to date.
Perform the following steps to ensure that an unexpected failover does not
occur during the replacement process.
To replace a DPU in a backup pair:
1.
Make sure there are no severe outstanding alarms from the DPU
which is to remain in service, then press its Takeover switch.
2.
Turn the keylock of the DPU being replaced to the Offline position
(fully counter-clockwise).
3.
Without disconnecting any cables, pull the DPU being replaced far
enough out of its chassis to disconnect power, then wait until all its
LEDs have turned off; this may require up to 30 seconds.
4.
Disconnect the backup cable from the DPU being replaced; DO NOT
disconnect the other end of the cable from the DPU which is to
remain.
5.
On the new DPU, verify that the NiCd battery pack is installed and
plugged correctly into P10 connector on the motherboard.
Additionally, verify that protective connectors (Part number 081389)
are installed in the IOM and CPU load connectors.
6.
Replace the DPU with the new unit, position the new DPU into the
top and bottom card guides of the chassis, but DO NOT push the new
6-5

unit in far enough to apply power to it.
6-6
7.
Set the backup DIP switches on the new DPU to match the unit which
was removed.
8.
Set the station number rotary switches to match the unit that was
removed.
9.
Set front panel mode switches 1, 2, and 8 to the left, and set mode
switch 4 to the right to demand a Cold startup.
10.
Connect the backup cable to the new DPU. Note that the cable end is
keyed so that it can only be inserted one way.
11.
Carefully slide the module forward, verifying that the connector pins
on the solder side of the module engage the corresponding contact
guides on the chassis assembly.
12.
When the contacts are engaged and resistance is felt, firmly press on
the front panel of the module front plate to make the simultaneous
connections at the front and rear. Apply pressure to the left of the
LEDs to place the force directly in line with the printed circuit card of
the module.
13.
14.

counting down from 0F to 06. Once it begins communicating, a
healthy DPU will display a rapidly flickering number whose value is
predominantly 07.
15.
16.
Reload the new DPU using maxTOOLS at a maxSTATION or the

Dump/Reload mode at an Operator Station.
17.
Acknowledge all alarms from the new DPU.
18.
Display Interaction Page 9 of the new DPU at a maxSTATION or

Operator Station. Locate the Backup? Field and type y for yes; locate
the Startup? Field and type y for yes.
19.
If the new DPU is the primary of the pair, make sure the secondary is
displaying the alarm DPU Pair is Running on Secondary. If the DPU
being replaced is the secondary, make sure the primary is displaying
the alarm Backup Link Timeout. This is done to make sure that there
are no higher priority alarms.
Starting the DPU

20.
Place the keyswitch of the new DPU in the Run or Locked mode.
21.
If the new DPU is the primary of the pair, wait at least 10 seconds to
allow its database to be updated, then press its Takeover button to give
it control.
22.
Acknowledge all DPU alarms and make sure they all clear.
23.
If the DPU is to be shipped or put in storage, unplug the NiCd battery

pack from the P10 connector.
6-7
Chapter 7
Using Interaction Pages
Accessing Displays
You may access Interaction Page displays 9 through 13 from the
maxSTATION to view information and data specifically related to the DPU.
These specific Interaction Pages are covered in this chapter in some detail.
To access an Interaction Page display:
1.
Bring up the maxVUE Runtime main menu.
2.
Click the System Status button on the standard Vertical Toolbar to

open the System Status display.
3.
Click the Int Page button appearing on the Horizontal Toolbar.
Using Interaction Page 9 Display with a Workstation

Use Interaction Page 9 to display the DPU configuration data sent by a
Work-Station. Refer to Figure 7-1.
Startup
The Startup? prompt appears when manual intervention is required,
following a cold startup or fatal alarm. For example, an I/O module fails and
is not configured as an alarm-only module.
Backup Option
DPUs can be paired in a redundant configuration as described in Chapter 5.
To configure the backup option, enter Y in the Backup field.

Digital Input Filter Time Field
Digital Input Filter time is in milliseconds; the default is 10 milliseconds.
This digital filter can be used in place of, or with, the jumper enabled
hardware lag filter on the Model IOP DI modules.
Serial Ports Field

You may connect asynchronous serial devices to serial ports 1 and 2. The
protocols and parameters for these devices are configured here. For
additional information about serial links, refer to Publication 277574, DPU
Embedded Serial Links User's Guide.
Lockout and Log Options Field

In the Lock position, you may disallow certain data DPU Bus operations
from MIS, HOST, REloads, or Screen Edits.
DPU Configuration Page
Revision
Level
Date 14/OC/96
Time 09:32:12
MODE Run
DHW 5.0
CP 5.0
IOM 5.0
Model 530 Configuration

Stat Page
Active
Backup N
DIGITAL
FILTER TIME
10 MSEC
SERIAL I/O PORTS

Port
No
Baud
Rate
Link Type
(0-255)
Bits/Char
(5,6,7,8)
Stop
(1,2)
Parity
(O,E,N)
XON/OFF
IN OUT
RTS/CTS
IN OUT
J6
J7
9600
9600
25 MODB
214 Umax
8
8
1
2
O
N
NN
NN
NN
NN
MIS
MIS
N HOST?
N HOST?
RELOAD?
RELOAD?
SCREENS? N
SCREENS? N
LOCK OUT ACTIONS

LOG EDIT ACTIONS
Figure 7-1. Interaction Page 9 Display with Sample Configuration.
Using Interaction Page 9 Display with an Operator Station

Use Interaction Page 9 to configure the DPU if a Model 585 Operator
Station is being used instead of a maxSTATION. Refer to Figure 7-2.
7-2

Before you can edit configuration data on Interaction Page 9, you must place
the DPU in offline mode. While you may make entries on this page only in
Offline mode, they do not take effect until either Run or Locked mode is
entered.
Any questionable entries on this page are automatically highlighted in red.
For example, you entered a Z instead of an I or O for a DIO module. The
Interaction Page 9 section title, where the questionable entry was made, also
becomes highlighted.
HWY 1 STA 33 INTERACTION PAGE 9
DPU Configuration Page
Revision
Level
Date 14/OC/96
Time 09:32:12
MODE Run
DHW 5.0
CP 5.0
IOM 5.0
Model 585 Configuration

Stat Page 10
Active
Backup? N
DIO Inventory
1
2
3
4
5
6
7
8
I = Input,
9
10
11
12
13
14
15
16
AI Inventory
QUAD1
QUAD2
QUAD3
QUAD4
O = Output,
17
18
19
20
21
22
23
24
Address
by 16
Alarm
Only
A = Alarm Only
25
26
Digital
27
Filter Time
28
10 msec
29
30
31
Channels
1-15
Linearization
( 1-15)
(16-30)
(33-47)
(48-62)
AI PAGE
DATA PT
14
15
14
15
14
15
14
15
Redundant I/O Address Ranges (R = Redundant, C = Common)

0
C
16
C
32
C
48
C
64
C
80
C
96
C
112
C
128
C
144
C
160
C
176
C
192
C
208
C
224
C
SERIAL I/O PORTS

Port
No
Baud
Rate
Link Type
(0-255)
Bits/Char
(5,6,7,8)
Stop
(1,2)
Parity
(O,E,N)
XON/OFF
IN OUT
RTS/CTS
IN OUT
J6
J7
9600
9600
25 MODB
214 Umax
8
8
1
2
O
N
NN
NN
NN
NN
N HOST?
N HOST?
RELOAD?
RELOAD?
LOCK OUT ACTIONS

LOG EDIT ACTIONS
MIS?
MIS?
SCREENS? N
SCREENS? N
Figure 7-2. Interaction Page 9, Operator Station Version.
The DPU will not become active until Interaction Page 9 is completely
configured and the keylock switch is in the Run or Locked position.
7-3

The following sections describe the expected entries and automatic defaults
on Interaction Page 9.
Startup
The startup? prompt appears when manual intervention is required
following a cold startup or fatal alarm. (For example, an I/O module fails
and is not configured as an alarm-only module.) After Interaction Page 9 is
reviewed and configured, enter Y in the entry field to place the DPU into
operation. Ensure that the keyswitch is in the Online (Run or Locked)
position.
Backup Option Field

DPUs can be paired in a redundant configuration as described in Chapter 5.
To configure the backup option, enter Y in the Backup field.
Stat Page Field

This field determines what is shown on Interaction Page 8. The default for
this field, 10, places the I/O status and event queue display on page 8.
During configuration this field may be changed to 11, DPU Serial Links
Status; 12, DPU Bus Performance Statistics; or 13, High Speed Digital I/O
Tabular Display.
DIO Inventory Field

The Digital Input/Output (DIO) Inventory can accept 30 entries in the ranges
1 to 15 and 17 to 31.
Enter I or O to indicate input/output modules.
Examples:
Append an A to indicate that loss or failure of one or more of these modules

is not a fatal alarm, as would be the default. (Any fatal alarm forces the DPU
to Offline mode.)
Examples:
7-4
IA
OA

The default is all blank fields. When no module at a given address is desired,
enter blanks at that location. Note that DIO modules need not be at
consecutive addresses.
For Fast Digital Inputs, a maximum of 25 digital input boards can be used.
Digital Input Filter Time Field

Digital Input filter time is in milliseconds; the default is 10 milliseconds.
This digital filter can be used in place of, or with, the jumper enabled
hardware lag filter on the Model IOP DI modules.
Analog Input Inventory Field

The Analog Input (AI) Inventory field on Interaction Page 9 contains three
columns. Each column can accept four entries.
The first column is for the four potential high-level Al modules needed to fill
the Analog (Process) Inputs Page. Enter the base module number (divisible
by 16, and greater than or equal to 32).
The second column is for As to specify alarm only.
Use the third column to specify the number of channels to be scanned of the
15 possible channels. This field is used when Quad PAT output modules are
used. For example, if two PAT output modules, with addresses of 48 and 62,
are used, quad one could be configured for address 48, with eight channels
scanned. Defaults are all blank fields.
Redundant I/O Address Ranges Field

When the Y adapter is used for a combined shared and redundant I/O bus,
ranges of modules must be specified as either redundant (R), common (C), or
blank if no modules reside in the specified range. For example, address 16
represents address ranges 16 through 31.
Lockout and Log Options Field

In the Lock position, you may disallow certain DPU Bus operations from
MIS, HOST, REloads, or Screen Edits.
Serial Ports Field

You may connect asynchronous serial devices to serial ports 1 and 2. The
protocols and parameters for these devices are configured here. For
additional information about serial links, refer to Publication 277574, DPU
Embedded Serial Links User's Guide.
7-5
Interaction Page 10
The I/O Module Status display shows all possible addresses on the I/O bus.
The status of each address (active, standby, communication problem or no
module) is highlighted in either green, yellow, red or black.
I/O MODULE STATUS

0
1
2
16
17
18
32
33
34
48
49
50
64
65
66
80
81
82
96
97
98
112 113 114
128 129 130
144 145 146
160 161 162
176 177 178
192 193 194
208 209 210
224 225 226
240 241 242
Last Bad Module =
3
19
35
51
67
83
99
115
131
147
163
179
195
211
227
243
4
20
36
52
68
84
100
116
132
148
164
180
196
212
228
244
5
21
37
53
69
85
101
117
133
149
165
181
197
213
229
245
6
22
38
54
70
86
102
118
134
150
166
182
198
214
230
246
7
23
39
55
71
87
103
119
135
151
167
183
199
215
231
247
8
24
40
56
72
88
104
120
136
152
168
184
200
216
232
248
9
25
41
57
73
89
105
121
137
153
169
185
201
217
233
249
10
26
42
58
74
90
106
122
138
154
170
186
202
218
234
250
11
27
43
59
75
91
107
123
139
155
171
187
203
219
235
251
12
28
44
60
76
92
108
124
140
156
172
188
204
220
236
252
13
29
45
61
77
93
109
125
141
157
173
189
205
221
237
253
14
30
46
62
78
94
110
126
142
158
174
190
206
222
238
254
15
31
47
63
79
95
111
127
143
159
175
191
207
223
239
255
EVENT QUEUE POINTERS

PUT
01
02
03
04
05
06
07
8489F4
820230
820230
820230
820230
820230
820230
820230
20
00
00
00
00
00
00
00
08
09
10
11
12
13
14
15
820230
820230
820230
820230
820230
820230
820230
820230
00
00
00
00
00
00
00
00
16
17
18
19
20
21
22
23
820230
820230
820230
820230
820230
820230
820230
820230
00
00
00
00
00
00
00
00
24
25
26
27
28
29
30
31
820230
820230
820230
820230
820230
820230
820230
820230
00
00
00
00
00
00
00
00
Figure 7-3. Interaction Page 10, I/O Module Status and Event Queue Pointers.
Green (Model IOP I/O) or blue (Field I/O) highlighting indicates that an I/O
module is present at that address and there are no communication problems
with the module. In a redundant I/O backup configuration, the module
address can assume this color in both the active and inactive DPUs.
Yellow highlighting indicates that the system is set up for shared I/O (two
DPUs with a common I/O string) and a module is present at that address.
The module address is highlighted in yellow for the inactive DPU and will
change to green when the DPU assumes control.
Red highlighting indicates that some process (Data Blocks, Process Inputs,
Control Blocks, or ExCEL) is trying to access a module at that address but
either no module is present or the module has a communication problem. If
the communication problem is intermittent, the address will only be red for 4
7-6

seconds after the last unsuccessful scan. In the case where only ExCEL is
trying to access the module, ExCEL must access the module frequently
enough for the error to persist.
SERIAL PORT J6 ExCEL
OK TRANSACTIONS
NO. OF DATA BLOCKS

NO. OF MESSAGES/SCAN
LINK SCAN TIME (MS)
0
0
0
INPUT QUEUE
OUTPUT QUEUE 0
BUFFER OVERRUNS
CHECKSUM ERRORS
FAILED TO SENDS
LINK LEVEL ERRORS
RETRIES
TIMEOUTS
UNEXPECTED CHARACTERS
LAST NAK CODE
0
0
0
0
0
0
0
0
BUFFER OVERRUNS
CHECKSUM ERRORS
FAILED TO SENDS
LINK LEVEL ERRORS
RETRIES
TIMEOUTS
LAST NAK CODE
0
0
0
0
0
0
0
0
SERIAL PORT J7 ExCEL

OK TRANSACTIONS
NO. OF DATA BLOCKS

NO. OF MESSAGES/SCAN
LINK SCAN TIME (MS)
0
0
0
INPUT QUEUE
OUTPUT QUEUE
0
0
Figure 7-4. Interaction Page 11, Serial Port Status Display.
Black highlighting indicates that no I/O module is present and no process is

attempting to access that address. Note that if two modules are present at the
same address, the DPU will not be able to communicate with either module
and the display will indicate that no module is present.
The Last Bad Module statistic field displays the address and time of the most
recent unsuccessful I/O scan.
Event Queue Pointer Information

Interaction page 10 also contains Event Queue pointer information. The
Event Queue is an internal DPU buffer used to store events such as Sequence
of Events entries, process alarms, remote diagnostic alarms, time updates,
and operator edit actions. The Event Queue pointer table shows the memory
address (in hex) of the last event placed in the queue by the DPU (i.e., PUT
XXXXXX YY), and the memory location of the last event removed from the
queue by each of the 31 possible high traffic loop stations during normal
operation (e.g., 01 XXXXXX YY). The last two digits in the field indicate
how many times the queue has wrapped around.
7-7

Since the events are constantly being removed from the queue and processed
by the stations on each scan, the addresses for active dequeueing stations
(maxSTATIONs and Operator Stations) should be close to the address of the
DPU PUT pointer.
HIGHWAY PERFORMANCE STATISTICS
STATION = 36
TIME MASTER ADDRESS

LAST SENDER OF BAD DATA
TIME SYNC MSGS IGNORED
36
0
0
TOKEN PASSES PER SECOND= 2
COMMAND RESPONSE
REJECTS
MASTERSHIPS RECEIVED = 26273

STATUS BROADCASTS = 65
TOTAL Q/R TRANSACTIONS = 1815
RECEIVED FRAMES WITH ERROR 101
UNFINISHED TRANSMIT QUERIES 0
LAST REJECTED STATION

LAST REJECTED QUERY
LAST REJECTED PTID TYPE
LAST REJECTED PTID INDEX
LAST REJECTED ITEM
LINK REJECTS
READ SINGLE ITEM
WRITE SINGLE ITEM
READ MULT ITEMS IEEE
WRITE MULT ITEMS IEEE
READ THESE ITEMS
READ SINGLE ITEM/STS
WRITE THESE ITEMS IEEE
READ THESE ITEMS/QUALITY
OLD SCAN TABLE MESSAGES
NEW SCAN TABLE MESSAGES
30
25
FF
FF
FF
0
152
181
2
243
34
39
0
0
0
40
CRC ERRORS = 2304

STALLOUT RECOVERIES = 0
OVERRUN ERRORS = 9
RECEIVE FRAME LENGTH ERRORS= 0
ABORTS RECEIVED = 0
ABORTS TRANSMITTED = 0
CTS LOST = 0
DCD LOST = 90
CTS NOT ACTIVE = 0
DCD ACTIVE AT TX TIME = 2
MESSAGE RETRIES = 160
UNEXPLAINED ERRORS = 0
HEX MEMORY DUMP 000000

TOTAL DHW DIAGNOSTIC ALARMS= 0
CW OPTICAL CABLE CHANGES = 0
CCW OPTICAL CABLE CHANGES= 0
CW ELECTRICAL CABLE CHANGES
CCW ELECTRICAL CABLE CHANGES= 2
PERMANENT NEXT STATION ADDRESS = 48
D7 01 F4 IF F8 FF 2E 94
77 04 00 50 00 00 00 00
0
Figure 7-5. Interaction Page 12, Highway Performance Statistics Page.
Interaction Page 11
Interaction page 11 contains serial link statistics for PLC links and HCI links
that may be connected to the serial ports of the DPU. Refer to Figure 7-4.
These statistics are cleared during any offline to online transition. Refer to
Publication 277574, DPU Embedded Links User's Guide, for more
information about these statistics. Refer to the following table for a
description of HCI link files.
7-8
OK TRANSACTIONS
Count of successful query/response

transactions between the PC and DPU.
BUFFER OVERRUNS
Count of messages received from PC

that were too long to be valid.

CHECKSUM ERRORS
Count of queries received

checksum errors from PC.
FAILED TO SENDS
Count of nonimmediate
attempted to be sent.
Count of unexpected
received from the PC.
with
queries
characters
All other statistics for HCI link are not valid.
Interaction Page 12
Interaction Page 12 contains the DPU Bus performance statistics display
show-ing the diagnostic counters for the network. The statistics are
cumulative from the last RZAP command, which is initiated from the
Highway Status display on the maxSTATION. Refer to Figure 7-5,
Interaction Page 12, Highway Performance Statistics Page. Refer to
Publication 277581 for descriptions of each field appearing on the left side
of the display.
The following table describes the right column statistics appearing in
Interaction Page 12:
COMMAND
REJECTs
RESPONSE Count of the Immediate queries sent to

this station that were rejected.
LAST REJECTED STATION
Highway address (in decimal) of the last

station that issued an Immediate query
that was rejected.
LAST REJECTED QUERY
Immediate query type (in decimal) of the

last Immediate query that was rejected.
LAST REJECTED PTID TYPE
PTID type field (in hex) of the last

database access failure. If the rejected
query above does not use a PTID the
type displayed will be FF.
LAST REJECTED PTID index
PTID slot/channel field (in hex) of the

last database access failure. If the
rejected query above does not use a
PTID the index displayed will be FF.
LAST REJECTED ITEM
Item number (in hex) of the last database

access failure. If the rejected query
above does not use an item number field
7-9

the item displayed will be FF.
READ SINGLE ITEM
Count of read single item queries

processed by this DPU since reset.
WRITE SINGLE ITEM
Count of write single item and write

single item IEEE queries processed by
this DPU since reset.
READ MULT ITEMS IEEE
Count of read multiple items queries

WRITE MULT ITEMS IEEE
Count of write multiple items queries

READ THESE ITEMS
Count of read these items and read these

items IEEE queries processed by this
DPU since reset.
READ SINGLE ITEM/STS
Count of read single with status queries

processed by this DPU since reset. The
read single item with status query is
normally issued by other DPUs and
Model 552 controllers to perform
Control Block and Data Block Receives.
Interaction Page 13
Interaction Page 13 contains the DIO tabular display; the fields are described
below:
Table 7-1. DIO Tabular Display.
TB01-TB32
Logical name of Fast DIO board 1-32.
T/F
Bit value: T = true = 1, F = False = 0.

For each bit in automatic mode, its state (T/F) is shown on
a yellow or green field background. For each bit in
manual mode, its state is shown on a black background.
7-10
I/O address
Physical I/O bus address of TBxx. This value can be

0-239 (0 = phantom).
Module type
DIO I/O module type input (IN) or output (OUT).

For modules configured to only alarm on failure, the type (IN or OUT) will
be in black on a yellow or green field background. If the module is
configured for a fatal error on failure (DPU goes offline), the type will be
shown in yellow or green on a black field background.
DIGITAL TABULAR DISPLAY
MODULE
TYPE
TBOL
TBO2
TBO3
TBO4
TBO5
TBO6
TBO7
TBO8
TBO9
TBLO
TBLI
TB12
TB13
TB14
TB15
TB16
IN
OUT
TB17
TB18
TB19
TB20
TB21
TB22
TB23
TB24
TB25
TB26
TB27
TB28
TB29
TB30
TB31
TB32
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
OUT
I/O
ADDRESS
10
11
12
13
14
15
16
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
TBOI
TBO2
TBO3
TBO4
TBO5
TBO6
TBO7
TBO8
TBO9
TBIO
TBll
TB12
TB13
TB14
TB15
TBI6
1
2
0
4
0
0
0
0
0
0
0
0
0
0
0
0
1
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
2
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
3
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
4
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
5
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
6
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
7
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
8
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
9
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
10
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
11
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
12
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
13
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
14
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
15
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
16
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
TBI7
TB18
TB19
TB20
TB21
TB22
TB23
TB24
TB25
TB26
TB27
TB28
TB29
TB30
TB31
TB32
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Figure 7-6. Interaction Page 13, Digital Tabular Display.
7-11
Chapter 8
Alarms and Diagnostics
Annunciation of Alarms
Diagnostic alarms originating at a DPU are posted as remote alarms on the
maxSTATION Alarm List. Refer to Publication 277558, Alarm Message
Reference Guide, for a description of these alarms. DPU front panel LEDs
also indicate certain fatal diagnostic alarms.
Front Panel Numeric LEDs

During normal operation, the numeric LEDs reflect the activity of the DPU
Bus Card). If a DPU is reset, it initially displays 88; during its restart cycle, it
displays FF, progresses through a series of steps counting down from 0F to
06, then goes online. Once online, a healthy DPU typically displays a rapidly
flickering number whose value is predominantly 07. If a DPU is
disconnected from the data DPU Bus, it displays a steady value of 07.
If a DPU has a failure which prevents the DPU Bus Card from working
properly, the DPU will drop off the data DPU Bus. Front panel LEDs will
then be used to display two diagnostic codes alternating every 1.5 seconds,
one reflecting the condition detected by the DPU Bus Card, and the other
reflecting the highest priority alarm reported by any of the processors. The
DPU Bus Card reports the following detected conditions:
DA
The DPU Bus address set on the front-panel rotary switches is

illegal (e.g., 00).
DC
Jabberhalt timeout; the DPU Bus Card transmitted on the DPU Bus
too long.
DF
The DPU Bus Card either detected a stack imbalance or executed

an illegal instruction.
The alarm code alternating with one of the above DPU Bus Card codes may
be any of the alarm codes listed in the Alarm Message Reference Guide. In
most cases, the two codes are independent; in a few special cases, one may
be the cause of the other. The most likely of those special cases is DC
(jabberhalt) combined with one of the following:
8-2
F0
The DPU Bus Card waited for a response from the Control
Processor (CP) which was never received, and the CP reported no
other fatal alarm condition.
FD
The DPU Bus Card waited for a response from the CP which was
never received because the CP determined that its program code
had been corrupted (checksum error).
FE
The DPU Bus Card waited for a response from the CP which was
never received because the CP re-executed its startup code
unexpectedly (jump or return to address 0).

MAX DNA DPU - A1

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Model PDP DPU

Copyright 1999-2001 by Metso Automation MAX Controls Inc.

Metso Automation MAX Controls 277573

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

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

Metso Automation MAX Controls 277573

Model PDP DPU Installation, Preparation and Adjustment

Metso Automation MAX Controls 277573

The Distributed Processing Unit described in this publication consists of two

Metso Automation MAX Controls 277573

Distributed Processing Unit Hardware

Metso Automation MAX Controls 277573

Model PDP DPU Installation, Preparation and Adjustment

Distributed Processing Unit Specifications

Storage temperature range

Relative humidity range

24 Vdc 4 Vdc, 1.2 amps

Mounting the DPU

Positioning the DPU

Metso Automation MAX Controls 277573

Wiring the DPU

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

Metso Automation MAX Controls 277573

All DPU controls, indicator lamps,

Mode Select DIP Switch Settings

Distributed Processing Unit

The mode switches, located at the top of

Metso Automation MAX Controls 277573

Model PDP DPU Installation, Preparation and Adjustment

Data Highway Area

Figure 2-2. Upper Front Panel Area

Metso Automation MAX Controls 277573

DPU Front Panel

To convert a two-digit hexadecimal number

Two LED Displays

Metso Automation MAX Controls 277573

Model PDP DPU Installation, Preparation and Adjustment

Status Section (LEDs)

DPU Hardware Status LEDs

What the Colors Mean

Green = DPU online and active.

Red = nickel cadmium or lithium battery bad.

Green = DPU powered.

Figure 2-3. Status LEDs

Metso Automation MAX Controls 277573

DPU Front Panel

What the Colors Mean

Green = serial port 1 transmitting.

Green = serial port 2 transmitting.

Status Section LED Indicators

all points good

all points good

all points good

all points good

Backup Status LEDs

What the Colors Mean

green = Receiving data.

Metso Automation MAX Controls 277573

Model PDP DPU Installation, Preparation and Adjustment

Backup DIP Switch Settings

Metso Automation MAX Controls 277573

DPU Front Panel

Keyslot diagonal, one-quarter turn counterclockwise from