Fs 99504

Fail Safe ControlService Manual

Revision 0303/2000

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 ofmerchantability and fitness for a particular purpose and makes no express warrantiesexcept 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 anyindirect, special or consequential damages. The information and specifications in thisdocument are subject to change without notice.

TotalPlant, TDC 3000 and Universal Control Network are U.S. registered trademarks ofHoneywell 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 ofHoneywell Safety Management Systems B.V.

FSC Service Manual

Table of Contents i

TABLE OF CONTENTS

Section 1 – Introduction1.1 Section overview.....................................................................................................................1

1.2 Scope of this document ..........................................................................................................1

1.3 Terminology ............................................................................................................................2

1.4 Competence of people............................................................................................................3

1.5 Precautions when working on FSC cabinets ..........................................................................4

1.6 Hardware requirements ..........................................................................................................6

1.7 Tools required .........................................................................................................................7

1.8 Reference documents.............................................................................................................8

Section 2 – Installation Guide2.1 Section overview...................................................................................................................11

2.2 Environmental conditions......................................................................................................122.2.1 Transportation conditions......................................................................................................132.2.2 Storage conditions ................................................................................................................142.2.3 Operating conditions .............................................................................................................15

2.3 FSC general cabinet layout...................................................................................................16

2.4 Unpacking, moving and placement.......................................................................................192.4.1 Unpacking the equipment .....................................................................................................192.4.2 Moving preparations .............................................................................................................232.4.3 Moving an FSC cabinet.........................................................................................................262.4.4 Interconnecting FSC cabinets...............................................................................................33

2.5 After placement.....................................................................................................................34

Section 3 – Connection of External Cables3.1 Section overview...................................................................................................................37

3.2 Interconnection wiring ...........................................................................................................38

3.3 Separation and routing of cables and wiring.........................................................................39

3.4 Earth/grounding cables .........................................................................................................403.4.1 Introduction ...........................................................................................................................403.4.2 Safety earth/ground ..............................................................................................................413.4.3 Instrument earth/ground........................................................................................................413.4.4 Ex(i) earth/ground .................................................................................................................41

3.5 Power/feeder cables .............................................................................................................423.5.1 Introduction ...........................................................................................................................423.5.2 Supply voltages.....................................................................................................................423.5.3 AC/DC power supply units ....................................................................................................433.5.4 Connecting AC power/feeder cables ....................................................................................433.5.5 DC power ..............................................................................................................................453.5.6 Connecting DC power/feeder cables ....................................................................................45

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TABLE OF CONTENTS (continued)

3.6 Field cables ...........................................................................................................................483.6.1 Introduction ...........................................................................................................................483.6.2 I/O module wiring using FTA-T devices................................................................................493.6.3 I/O module wiring using FTA-E .............................................................................................523.6.4 I/O module wiring using terminals.........................................................................................553.6.5 I/O module wiring using third-party devices..........................................................................58

3.7 Communication cables..........................................................................................................613.7.1 Introduction ...........................................................................................................................613.7.2 Connecting fiber optic cables................................................................................................623.7.3 Connecting trunk cables to taps............................................................................................663.7.4 Connecting other communication cables..............................................................................66

Section 4 – Power-Up of the FSC Cabinet4.1 Section overview...................................................................................................................69

4.2 Checks prior to power-up......................................................................................................704.2.1 Checking all signal wiring......................................................................................................704.2.2 Checking all incoming power ................................................................................................704.2.3 Checking AC power ..............................................................................................................704.2.4 Checking DC power ..............................................................................................................72

4.3 Performing the power-up ......................................................................................................734.3.1 Powering up a redundant system .........................................................................................734.3.2 Powering up a single system ................................................................................................734.3.3 Troubleshooting ....................................................................................................................734.3.4 Activities after power-up........................................................................................................74

Section 5 – Site Acceptance Test5.1 Section overview...................................................................................................................75

5.2 SAT definition and objective .................................................................................................76

5.3 Involved parties .....................................................................................................................77

5.4 Documentation required........................................................................................................77

5.5 Contents of the SAT document.............................................................................................79

Section 6 – General Maintenance Considerations6.1 Section overview...................................................................................................................81

6.2 Types of maintenance...........................................................................................................82

6.3 Corrective maintenance ........................................................................................................83

6.4 Actions before maintenance, service and modification.........................................................84

6.5 Actions during maintenance, service and modification.........................................................86

6.6 Actions after maintenance, service and modification............................................................87

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Section 7 – Preventive Maintenance7.1 Section overview...................................................................................................................89

7.2 Preventive maintenance overview ........................................................................................90

7.3 Three-monthly preventive maintenance ...............................................................................917.3.1 Overview ...............................................................................................................................917.3.2 Checking the voltages to the Central Part ............................................................................917.3.3 Checking the temperatures in the Central Part.....................................................................967.3.4 Checking air flow obstruction ................................................................................................987.3.5 Checking the correct operation of the fans ...........................................................................987.3.6 Checking for earth faults .......................................................................................................997.3.7 Checking the loop status of signals ....................................................................................1017.3.8 Checking the forced status of signals .................................................................................1037.3.9 Checking for paint damage.................................................................................................1047.3.10 Checking the availability of spare parts ..............................................................................1047.3.11 Checking the system diagnostics .......................................................................................1057.3.12 Checking the backup of the application files.......................................................................106

7.4 Preventive maintenance during every power-down............................................................1077.4.1 Overview .............................................................................................................................1077.4.2 Checking all DC voltages....................................................................................................1087.4.3 Checking the power distribution fuses ................................................................................1097.4.4 Checking the AC voltages...................................................................................................1107.4.5 Checking the correct operation of the PSUs.......................................................................1117.4.6 Checking for dust concentration .........................................................................................1127.4.7 Replacing all dust filters ......................................................................................................1127.4.8 Checking the fasteners on the power distribution rails .......................................................1137.4.9 Checking all cable clamps ..................................................................................................1137.4.10 Checking all shield connections..........................................................................................1147.4.11 Checking all earth/ground connections...............................................................................1157.4.12 Testing all hardware I/O......................................................................................................1167.4.13 Testing all communication links to external devices...........................................................118

Section 8 – Troubleshooting and Fault-Finding8.1 Section overview.................................................................................................................121

8.2 Notification of alarms and errors.........................................................................................122

8.3 Retrieving diagnostic information from the FSC system.....................................................1238.3.1 Visible and/or audible alarms..............................................................................................1238.3.2 FSC Navigator software......................................................................................................1238.3.3 Diagnostic and Battery Module (DBM) ...............................................................................1258.3.4 Sequence-of-Event (SOE) station ......................................................................................125

8.4 Acting on the information retrieved .....................................................................................127

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Section 9 – Service and/or Modification to the FSC Cabinet9.1 Section overview.................................................................................................................129

9.2 Service and modification overview......................................................................................1309.2.1 Important considerations.....................................................................................................1309.2.2 On-line modification ............................................................................................................131

9.3 Hardware service and/or modification to the FSC cabinet..................................................1329.3.1 Introduction .........................................................................................................................1329.3.2 Adding a communication module........................................................................................1329.3.3 Adding an I/O rack ..............................................................................................................1339.3.4 Adding I/O modules.............................................................................................................1339.3.5 Adding wiring to existing circuit breaker .............................................................................1349.3.6 Changing converter modules ..............................................................................................1359.3.7 Calibrating transmitters .......................................................................................................1389.3.8 Key coding ..........................................................................................................................1389.3.9 Updating documentation .....................................................................................................139

9.4 Software service and/or modification to the FSC cabinet ...................................................1409.4.1 Introduction .........................................................................................................................1409.4.2 Verifying the application files ..............................................................................................1409.4.3 Backing up the application files...........................................................................................1419.4.4 Adding/changing FLDs........................................................................................................1429.4.5 Renumbering FLDs.............................................................................................................1439.4.6 Adding/changing timers ......................................................................................................1439.4.7 Changing counters ..............................................................................................................1439.4.8 Loopback of sheet references.............................................................................................1449.4.9 EPROM/RAM size...............................................................................................................1469.4.10 Square root of a negative value ..........................................................................................1469.4.11 Divide by zero .....................................................................................................................1469.4.12 Range-checking errors........................................................................................................147

Section 10 – Training Courses10.1 Section overview.................................................................................................................149

10.2 Training overview................................................................................................................150

10.3 Fail Safe Controller Managers Overview course (4501).....................................................151

10.4 Introduction to IEC 61508 course (4504)............................................................................152

10.5 Fail Safe Controller Implementation course (4508) ............................................................153

10.6 Fail Safe Controller Maintenance course (4505) ................................................................154

10.7 Fail Safe Controller On-Line Modification course (4502)....................................................155

10.8 Fail Safe Controller Advanced course (4512).....................................................................156

10.9 Fail Safe Controller Total Package course .........................................................................157

10.10 Customized training courses...............................................................................................157

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Section 11 – Decommissioning11.1 Section overview.................................................................................................................159

11.2 Decommissioning overview ................................................................................................160

11.3 Decommissioning procedure ..............................................................................................16111.3.1 Checking system operation.................................................................................................16111.3.2 Powering down the FSC cabinet ........................................................................................16111.3.3 Disconnecting all cables .....................................................................................................16211.3.4 Removing all recyclable items ............................................................................................16511.3.5 Removing all batteries ........................................................................................................16611.3.6 Removing the FSC cabinet .................................................................................................166

Appendix A – Plinth LayoutsA.1 Section overview.................................................................................................................169

A.2 Introduction .........................................................................................................................170

A.3 No plinth for one PS 4806 cabinet ......................................................................................171

A.4 Plinth for one PS 4806 cabinet ...........................................................................................172

A.5 Plinth for two PS 4806 cabinets..........................................................................................173

A.6 Plinth for three PS 4806 cabinets .......................................................................................174

A.7 No plinth for one PS 4808 cabinet ......................................................................................175

A.8 Plinth for one PS 4808 cabinet ...........................................................................................176

A.9 Plinth for two PS 4808 cabinets..........................................................................................177

A.10 Plinth for three PS 4808 cabinets .......................................................................................178

A.11 Plinth for four PS 4808 cabinets .........................................................................................179

Appendix B – Stopping / Powering Down the FSC SystemB.1 Section overview.................................................................................................................181

B.2 Central Part configuration ...................................................................................................182

B.3 Stopping one CP of an FSC system with redundant CPs ..................................................183

B.4 Stopping both CPs of an FSC system with redundant CPs................................................185

B.5 Powering down an FSC system with redundant CPs .........................................................188

B.6 Stopping the CP of an FSC system with a single CP .........................................................192

B.7 Powering down an FSC system with a single CP...............................................................194

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Appendix C – Starting Up / Powering Up the FSC SystemC.1 Section overview.................................................................................................................197

C.2 Central Part configuration ...................................................................................................198

C.3 Starting one CP of an FSC system with redundant CPs ....................................................199

C.4 Starting both CPs of an FSC system with redundant CPs..................................................203

C.5 Powering up an FSC system with redundant CPs..............................................................209

C.6 Starting the CP of an FSC system with a single CP...........................................................215

C.7 Powering up an FSC system with a single CP ...................................................................218

Appendix D – Alarm/Error Messages and SolutionsD.1 Section overview.................................................................................................................223

D.2 General messages..............................................................................................................224

D.3 Analog input module 10102/x/x...........................................................................................225

D.4 Analog input module 10105/2/1 ..........................................................................................226

D.5 Analog output module 10205/2/1 ........................................................................................227

D.6 Communication errors with the FSC user station ...............................................................228

D.7 Output short circuit ..............................................................................................................229

D.8 Download not successful ....................................................................................................230

D.9 Process trip during an on-line modification.........................................................................231

D.10 Calculation errors ................................................................................................................232

Appendix E – ChecklistsE.1 Section overview.................................................................................................................235

E.2 Preventive maintenance overview ......................................................................................236

E.3 Checklist for three-monthly maintenance ...........................................................................238

E.4 Checklist for maintenance during power-down...................................................................241

Appendix F – Using FerritesF.1 Section overview.................................................................................................................245

F.2 Using ferrites .......................................................................................................................246

F.3 Ferrites on AC power/feeder cables ...................................................................................250

F.4 Ferrites on DC power/feeder cables ...................................................................................251

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Appendix G – Repair Handling and Ordering of Emergency Spare PartsG.1 Section overview.................................................................................................................253

G.2 Terminology ........................................................................................................................254

G.3 Handling of defective products/parts ..................................................................................255

G.4 Ordering of emergency replacements ................................................................................257

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Figures

Figure 1-1 ESD wrist-strap connected to ESD bonding point ..........................................................4Figure 2-1 Placement of an FSC cabinet onto lumber...................................................................27Figure 2-2 Placement using a mobile lifter.....................................................................................29Figure 2-3 Lifting equipment by mobile lifter or crane....................................................................30Figure 2-4 Moving the FSC cabinet using the roller method..........................................................31Figure 2-5 Eyebolt crane method...................................................................................................32Figure 3-1 Typical routing of internal wiring between I/O modules and FTA-T via SIC-Cs ...........49Figure 3-2 Bonding of shielded cables (FTA-T) .............................................................................51Figure 3-3 Typical routing of internal wiring between I/O modules and FTA-E via SIC-Cs ...........52Figure 3-4 Bonding of shielded cables (FTA-E).............................................................................54Figure 3-5 Typical layout of a SIC-P cable.....................................................................................55Figure 3-6 Bonding of shielded cables (terminals).........................................................................57Figure 7-1 Status of Diagnostic and Battery Module (DBM) ..........................................................94Figure 7-2 Viewing the I/O loop status .........................................................................................102Figure 7-3 Listing all forces in the system....................................................................................103Figure 7-4 Checking the system diagnostics ...............................................................................105Figure 7-5 Bonding of shielded cables.........................................................................................114Figure 8-1 Viewing the extended diagnostic information .............................................................124Figure 9-1 Off-sheet references and loopbacks...........................................................................144Figure A-1 No plinth for one Rittal PS 4806 cabinet.....................................................................171Figure A-2 Plinth for one Rittal PS 4806 cabinet ..........................................................................172Figure A-3 Plinth for two Rittal PS 4806 cabinets ........................................................................173Figure A-4 Plinth for three Rittal PS 4806 cabinets......................................................................174Figure A-5 No plinth for one Rittal PS 4808 cabinet.....................................................................175Figure A-6 Plinth for one Rittal PS 4808 cabinet ..........................................................................176Figure A-7 Plinth for two Rittal PS 4808 cabinets ........................................................................177Figure A-8 Plinth for three Rittal PS 4808 cabinets......................................................................178Figure A-9 Plinth for four Rittal PS 4808 cabinets ........................................................................179Figure F-1 Ferrite types ................................................................................................................246Figure F-2 Ferrite layout ...............................................................................................................247Figure F-3 Ferrites on AC power/feeder cables ...........................................................................250Figure F-4 Ferrites on DC power/feeder cables ...........................................................................251

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Tables

Table 2-1 Move preparation checklist ...........................................................................................24Table 2-2 Preparing the electronics room.....................................................................................25Table 2-3 Fork lift considerations..................................................................................................27Table 2-4 Mobile lift considerations ..............................................................................................28Table 2-5 Roller method considerations .......................................................................................31Table 3-1 Routing of cables carrying different voltages................................................................39Table 9-1 Conversion table.........................................................................................................147Table 9-2 FSC register types ......................................................................................................147Table D-1 General, non module-specific messages ...................................................................224Table D-2 Messages related to 10102/x/x analog input modules ...............................................225Table D-3 Messages related to 10105/2/1 analog input module.................................................226Table D-4 Messages related to 10205/2/1 analog output module ..............................................227Table D-5 No communication with the FSC system....................................................................228Table D-6 Output short circuit......................................................................................................229Table D-7 Download not successful ............................................................................................230Table D-8 Process trip .................................................................................................................231Table D-9 Calculation errors........................................................................................................232Table E-1 Three-monthly maintenance checklist ........................................................................238Table E-2 Power-down maintenance checklist ...........................................................................241Table F-1 Würth and Kitagawa ferrites and their characteristics ................................................246Table F-2 Ferrite selection (example) .........................................................................................248Table F-3 Ferrite selection table .................................................................................................249

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Abbreviations

A/D.............................................................................................................................................Analog/digitalAC...................................................................................................................................... Alternating currentAI..................................................................................................................................................Analog inputAK ................................................................................................ Anforderungsklasse (= requirement class)AO............................................................................................................................................. Analog outputAWG ..............................................................................................................................American Wire GageBCD ..............................................................................................................................Binary coded decimalc .........................................................................................................................................................commonCE............................................................................................................................. Conformité EuropéenneCh ...................................................................................................................................................... ChannelCOM ...................................................................................................................................... CommunicationCOSI ....................................................................................................................................Crimp-on snap-inCP................................................................................................................................................ Central PartCPU ............................................................................................................................. Central processor unitD/A.............................................................................................................................................Digital/analogDBM................................................................................................................Diagnostic and battery moduleDC..............................................................................................................................................Direct currentDCD ...................................................................................................................................Data carrier detectDCF .........................................................................................................................Digital Coded FrequencyDCS .......................................................................................................................Distributed control systemDI ..................................................................................................................................................Digital inputDIL .................................................................................................................................................Dual in-lineDIN............................................................................................................................Deutsche IndustrienormDoC.........................................................................................................................Declaration of ConformityDO ..............................................................................................................................................Digital outputDOS .............................................................................................................................Disk operating systemDSR ......................................................................................................................................... Data set readyDTR ................................................................................................................................. Data terminal readyEEA........................................................................................................................ European Economic AreaEEPROM ..................................................................Electrically erasable programmable read-only memoryELD............................................................................................................................. Earth leakage detectorEMC..................................................................................................................Electromagnetic compatibilityEN................................................................................................... Europäische Norm (European standard)EPROM.......................................................................................Erasable programmable read-only memoryESD............................................................................................................................. Electrostatic dischargeESD...............................................................................................................................Emergency shutdownEU......................................................................................................................................... European Unionext. ......................................................................................................................................................externalF.......................................................................................................................................................... Fuse(d)FAT ..........................................................................................................................Factory Acceptance TestFF .......................................................................................................................................................Flip-flopFLD’s ....................................................................................................................Functional Logic DiagramsFM............................................................................................................................................Factory MutualFS ......................................................................................................................................................Fail-safeFSC.......................................................................................................................................Fail Safe ControlFSC-DS ................................................................................................................FSC Development SystemFSC-SM .........................................................................................................................FSC Safety ManagerFSC-SMM .........................................................................................................FSC Safety Manager ModuleFTA .......................................................................................................................Field termination assemblyGND.....................................................................................................................................................Ground

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Abbreviations (continued)

HBD ............................................................................................................................... Horizontal bus driverHE..................................................................................................................................... Höheneinheit (= U)HF .......................................................................................................................................... High FrequencyHP................................................................................................................................Horizontal pitch (= TE)HSMS .............................................................................................Honeywell Safety Management SystemsHW................................................................................................................................................... HardwareH x W x D .................................................................................................................... Height x width x depthI/O .................................................................................................................................................Input/outputIC .......................................................................................................................................... Integrated circuitIEC............................................................................................... International Electrotechnical Commissionint. ........................................................................................................................................................ internalIP ........................................................................................................................................ Ingress protectionJ ...........................................................................................................................................................JumperLED.................................................................................................................................. Light-emitting diodeLSB...................................................................................................................................Least significant bitMEM ...................................................................................................................................................MemoryMUX............................................................................................................................................... Multiplexern/a............................................................................................................................................. not applicableNC..........................................................................................................................................Normally closednc ..............................................................................................................................................not connectedNFS............................................................................................................................................. Non fail-safeNO ........................................................................................................................................... Normally openNTC .............................................................................................................Negative temperature coefficientNVRAM.................................................................................................Non-volatile random-access memoryP/N...............................................................................................................................................Part numberPCB .................................................................................................................................Printed circuit boardPSD ........................................................................................................................ Power supply distributionPSU .................................................................................................................................... Power supply unitR ................................................................................................................................... Resistance / ResistorRAM........................................................................................................................ Random-access memoryRTS....................................................................................................................................... Request to sendSBD ......................................................................................................................................Single bus driverS-Bus ..............................................................................................................................................Single busSER ..................................................................................................................Sequence-of-event recordingSAT............................................................................................................................... Site Acceptance TestSIC................................................................................................................... System interconnection cableSIL .................................................................................................................................. Safety integrity levelSM ......................................................................................................................................... Safety ManagerSMM ......................................................................................................................... Safety Manager ModuleSMOD...................................................................................................... Second Means Of De-energizationSOE .................................................................................................................................Sequence of eventsSTP................................................................................................................................ Shielded twisted pairSW .................................................................................................................................................... SoftwareTE ........................................................................................................................................Teileinheit (= HP)TIB ...................................................................................................................... Transformer isolated barrierTPS................................................................................................................................. TotalPlant SolutionsTTL ......................................................................................................................... Transistor-transistor logicTTY....................................................................................................................................................TeletypeTÜV...........................................................................................................Technischer Überwachungsverein

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Abbreviations (continued)

U ....................................................................................................................................................Unit (= HE)UCN ...................................................................................................................... Universal Control NetworkUL ..........................................................................................................................Underwriters LaboratoriesUV....................................................................................................................................................UltravioletVac.............................................................................................................................. Volt alternating currentVBD.....................................................................................................................................Vertical bus driverV-Bus ............................................................................................................................................Vertical busVdc...................................................................................................................................... Volt direct currentWD.................................................................................................................................................. WatchdogWDG............................................................................................................................................... WatchdogWDR .................................................................................................................................Watchdog repeaterZIF ................................................................................................................................... Zero insertion force

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REFERENCES

FSC Documentation:

PublicationTitle

PublicationNumber

FSC Safety Manual R5xx FS90-5xx*

FSC Software Manual R5xx FS80-5xx*

FSC Hardware Manual FS02-500* '5xx' is the release number. For example, the Software Manual for FSC R510 is referencedas FS80-510, and the update for FSC R520 as FS80-520.

FSC-SM Documentation:

PublicationTitle

PublicationNumber

FSC Safety Manager Installation Guide FS20-500

FSC Safety Manager Implementation Guidelines FS11-500

FSC Safety Manager Control Functions FS09-500

FSC Safety Manager Parameter ReferenceDictionary FS09-550

FSC Safety Manager Configuration Forms FS88-500

FSC Safety Manager Service Manual FS13-500

FSCSOE Documentation:

PublicationTitle

PublicationNumber

FSCSOE – Basic Version FS50-1xx*

FSCSOE – Network Option FS51-1xx*

FSCSOE – Foxboro I/A Interface Option FS52-1xx*

FSCSOE – Yokogawa CS Interface Option FS53-1xx** '1xx' is the release number. For example, the Basic Version manual for FSCSOE R130 isreferenced as FS50-130.

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Service Manual

Section 1: Introduction 1

Section 1 – Introduction

1.1 Section overview

Section overview This section provides general information on the tools,documentation required, competence of people, and referencedocuments for maintenance, service and modification to Fail SafeControl (FSC) cabinets of Honeywell Safety Management Systems(HSMS). It covers the following topics:

Subsection Topic See page

1.1 Section overview............................................................................................... 11.2 Scope of this document .................................................................................... 11.3 Terminology ...................................................................................................... 21.4 Competence of people...................................................................................... 31.5 Precautions when working on FSC cabinets .................................................... 41.6 Hardware requirements .................................................................................... 61.7 Tools required................................................................................................... 71.8 Reference documents....................................................................................... 8

1.2 Scope of this document

Scope This document is intended for engineers and other technicalpersonnel who will perform any maintenance, service andmodification to a Fail Safe Control (FSC) cabinet.

Please note that this Service Manual is a generic document. Thismeans that not all items mentioned in this document may necessarilyapply to FSC cabinets in specific situations or applications.Every FSC cabinet is supplied with project-related documentationwhich provides detailed information and guidelines for the specificFSC cabinet(s).

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2 Section 1: Introduction

1.3 Terminology

Terminology The following terminology is important for proper understanding ofthis manual:

FSC system An FSC system consists of a Central Part (CP) section and/or I/Osection. The I/O modules are wired to the field terminationassemblies (FTAs) and/or terminals using system interconnectioncables (SICs). The FTAs and/or terminals may be located remotely(e.g. in a marshalling cabinet).

FSC cabinet An FSC cabinet consists of one or more cabinets. The followingitems 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.

Start ofan FSC system

An FSC system is (re)started if the power to the FSC cabinet has notbeen disconnected. This will typically be the case during on-linemodification (OLM) or after most maintenance tasks, e.g. exchangingCentral Part modules.

Power-up ofan FSC cabinet

An FSC system is powered up after all power to the FSC cabinet hasbeen disconnected. This will typically be the case during certainmaintenance tasks that require the power to be cut off, e.g. replacingbackplanes or supply input filters.

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1.4 Competence of people

Important!Any activities on the FSC cabinet may only be carried out byqualified, authorized and properly trained personnel. Failure tocomply with the regulations and guidelines contained in thisdocument may cause severe damage to the equipment and/orserious injury to people.

Training Personnel that is to perform any kind of maintenance, service and/ormodification to an FSC cabinet should have successfully completedthe 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 toSection 10 of this Service Manual.

In addition to the above standard training courses, customized trainingcan also be offered. These are specifically geared to the customer'sspecific needs. They will always be set up in cooperation with thecustomer, for example to focus on any discipline required for aparticular site.

Obtaininginformation ontraining

For detailed information on the above-mentioned training coursesplease contact your local Honeywell affiliate or Honeywell SMSRegional Delivery Center (RDC).

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1.5 Precautions when working on FSC cabinets

Importantconsiderations

A number of considerations are important for working on FSCcabinets:• Keeping the cabinet doors closed, and• Electrostatic discharge (ESD).

Each of these is discussed in more detail below.

Keep the doorsclosed

When not working on the FSC cabinet, make sure that you keep thedoors closed in order to prevent dust and other particles from enteringthe FSC cabinet. Also, the electromagnetic immunity of the FSCsystem is reduced if the cabinet doors are open. Devices such as radiotransmitters should preferably not be used close to an opened FSCcabinet.Make sure that you always close the cabinet doors after any operationspecified in this Service Manual.

Electrostaticdischarge (ESD)

It is important that you wear a properly connected electrostaticdischarge (ESD) wrist-strap while removing, handling and installingany electronic components (see Figure 1-1).

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 tothe ESD bonding point, which is located inside the cabinet. There isno danger of receiving a shock from an approved wrist-strap.

Be sure to keep any electronic component in a static-safe carryingpouch whenever it is not in use.An ESD kit is available through your local Honeywell serviceorganization.

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1.6 Hardware requirements

Hardwarerequirements

The following hardware requirements apply for working on FSCsystems:• 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 theFSC system contains Central Part modules that supportdownloading to flash memory.

• If RS-485 serial communication is used between the FSC systemand the FSC user station, an HSMS 07177/1/1 serial interface orother approved RS-485 interface is required.

• For testing spare parts, an FSC simulation unit or FSC training unitis required. For details refer to Appendix H of the FSC SoftwareManual ("Simulation Mode").

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1.7 Tools required

Tools Various tools are required during maintenance, service andmodification to the FSC cabinet. As a minimum, the following toolsare 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),• 3½-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.).

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1.8 Reference documents

Documentation The documentation required for the maintenance, service andmodification to an FSC cabinet can be split into two parts:• Project-related documentation, and• FSC user documentation.

Both are discussed in more detail below:

Project-relateddocumentation

FSC cabinets are supplied with project-related documentation whichprovides detailed information and guidelines for the specific FSCcabinet(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 ormore specific FSC cabinets.

Note:Always make sure that the latest versions of the project-relateddocumentation is available. This is not necessarily the "as-built"documentation.If you work with old and/or obsolete documentation, this maylead to problems and/or delays during maintenance, service andmodification.

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FSC userdocumentation

There is also generic user documentation that applies to all FSCsystems. This documentation provides technical details of the FSChardware 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 technicalspecifications of the FSC hardware modules and components.

• FSC Software Manual.This is the user manual to the FSC Navigator software, which isused to interface with the FSC system.

• FSC Safety Manual.This is a document which provides general information on safetyand safety-related systems, as well as implementation guidelines forFSC systems.

• FSC-SM documentation set.This is a set of manuals that provide information and guidelines forthe 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 thisdocument.

2. All references in this Service Manual made to the FSCSoftware Manual refer to Release 510 and higher.

3. All references in this Service Manual made to the FSCSafety Manual refer to Release 510 and higher.

4. All references in this Service Manual made to the FSC-SMdocumentation refer to the latest version of thisdocumentation.

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Left blank intentionally.

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Section 2: Installation Guide 11

Section 2 – Installation Guide


Section overview This section provides general information on environmentalconditions, transportation, unpacking, and installation of the FSCcabinet. It covers the following topics:


2.1 Section overview............................................................................................. 112.2 Environmental conditions................................................................................ 122.2.1 Transportation conditions ............................................................................... 132.2.2 Storage conditions .......................................................................................... 142.2.3 Operating conditions....................................................................................... 152.3 FSC general cabinet layout ............................................................................ 162.4 Unpacking, moving and placement ................................................................ 192.4.1 Unpacking the equipment ............................................................................... 192.4.2 Moving preparations ....................................................................................... 232.4.3 Moving an FSC cabinet .................................................................................. 262.4.4 Interconnecting FSC cabinets ........................................................................ 332.5 After placement............................................................................................... 34

Honeywell SMSrepresentative

It is recommended that a Honeywell SMS representative is presentduring the installation of the FSC cabinet. This is to ensure that thecorrect procedures are being followed. Moreover, should anyproblems arise during the installation, they can be solved on the spot.

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12 Section 2: Installation Guide

2.2 Environmental conditions

Environmentalconditions

The environmental conditions for FSC cabinets can be split intothree areas:• Transportation conditions,• Storage conditions, and• Operational conditions.

Each of these areas is discussed in more detail in subsections 2.2.1 to2.2.3.

Factory packing In order to minimize the exposure to humidity, keep the factorypacking intact during storage and transit. If it is necessary to unsealthe equipment (e.g. for customs clearance), add more desiccant andreseal the packing.

Mobile lifter /fork lift

For transportation of the FSC cabinet over short distances (e.g. fortransportation between the truck and storage location), a mobile lifteror fork lift can be used.

Important!Take all necessary action to ensure that the FSC cabinet isproperly secured during transportation to prevent damage to theequipment and/or serious injury to persons.

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2.2.1 Transportation conditions

Transportationconditions The transportation conditions for FSC cabinets are as follows:

• FSC cabinets are only to be transported using trucks that areequipped with the following:− air suspension,− a tail board, and− a full enclosure.

• Temperature: –25°C to +80°C (–13°F to +176°F),• Relative humidity: max. 95% (non-condensing)• Vibration (sinusoidal): excitation: sine-shaped with sliding freq.

frequency range: 10-150 Hzloads: 10 Hz - 57 Hz: 0.075 mm

57 Hz - 150 Hz: 1 Gno. of axes: 3 (x, y, z)traverse rate: 1 oct/min.

• Shock: 15 G in 3 axes (shock duration: 11 ms)• 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 andmimic panels, refer to the information provided by the equipmentmanufacturer.

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2.2.2 Storage conditions

Storageconditions The storage conditions for FSC cabinets are as follows:

• FSC cabinets are to be stored in their original packing.• Temperature: –25°C to +80°C (–13°F to +176°F),• Relative humidity: max. 95% (non-condensing)• Vibration (sinusoidal): excitation: sine-shaped with sliding freq.



• Shock: 15 G in 3 axes (shock duration: 11 ms)• 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 mimicpanels, refer to the information provided by the equipmentmanufacturer.

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2.2.3 Operating conditions

Operatingconditions The operating conditions for FSC cabinets are as follows:

• Operating temperature: 0°C to 60°C (32°F to 140°F),measured at the Central Part rack(s) by theDiagnostic and Battery Module (DBM).

• Relative humidity: max. 95% (non-condensing)• Vibration (sinusoidal): excitation: sine-shaped with sliding freq.



• Shock: 15 G in 3 axes (shock duration: 11 ms)

Other items For operating conditions of other items such as PCs, printers andmimic panels, refer to the information provided by the equipmentmanufacturer.

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2.3 FSC general cabinet layout

General This subsection discusses the general layout of FSC cabinets.Please note that FSC cabinets are always made according to customerrequirements, which means that deviations from the generaldescription below are possible.

Cabinet types 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)(31½ x 23½ x 78¾ in).

• PS 4808:Measurements: 80 x 80 x 200 cm (width x depth x height)

(31½ x 31½ x 78¾ in).

Cabinet plinth The FSC cabinet can be supplied with or without a plinth, dependingon the customer requirements.Appendix A of this Service Manual specifies the dimensions andlocations of the bolt-down holes for cabinets supplied with andwithout a plinth.

Maximum numberof cabinets

A maximum of four PS 4806 or four PS 4808 Rittal cabinets can bebuilt together and transported as one shipping section. This dependson the equipment mounted in the Rittal cabinets and the customerrequirements.

Height of cabinet The height of the above-mentioned Rittal PS 4806 and PS 4808cabinets does not include the plinth (normally 10 cm / 4 in) and thelifting eye bolts (5 cm / 2 in).The lifting eye bolts can be removed, if necessary.

Weight of cabinet The weight of the FSC cabinet depends on the hardware installed andcan go as high as 550 kg (1210 lb) per Rittal PS 4806 or PS 4808cabinet.

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IP rating By default, FSC cabinets have an Ingress Protection (IP) rating ofIP20 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 customerrequirements.

Front / rear access For easy access to the equipment mounted in the FSC cabinet, one ormore 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.

Swing frame For easy access to the rear of the circuit breaker rack(s), Central Partsrack(s) and I/O rack(s), the equipment is mounted in a swing frame.Opening the swing fame will also enable access to any equipmentwhich is mounted behind the swing frame.

Important!For safety reasons, do not open more than one swing frame at atime, even when the FSC cabinets are properly bolted to thefloor.

Bolting downcabinets

All FSC cabinets, once arrived at their final location, should be bolteddown to the floor for safety reasons.

Important!Opening swing frames when FSC cabinets are not properlybolted to the floor might tip over the FSC cabinets resulting insevere damage to the equipment and/or serious injury topersons.

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Cable entry FSC cabinets are designed according to customer requirements.The following cables may enter the FSC cabinet (depending on thespecifications):• Earth/ground cables,• Power/feeder cables,• Communication cables, and• Field cables.

Depending on the customer requirements, these cables may enter theFSC cabinet from the top and/or bottom. For bottom entry, slidingfloor 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 tothe cable support/clamp rail. The clamping devices should be able towithstand a 45 kg (100 lb) pull. This prevents damage inside the FSCcabinet when pulling on cables outside the FSC cabinet.

As a standard, the FSC cabinet includes a cable support/clamp rail atthe bottom and/or at the top. If a plinth is factory-mounted, the cablesupport/clamp rail will be mounted in the plinth.Depending on customer requirements, it is possible that no cablesupport/clamp rail is mounted. This will, for example, be the case if acable 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 aconditioned room as the equipment is delicate and the humidity mayaffect the equipment, resulting in corrosion.For details on the environmental condition refer to subsection 2.2 ofthis Service Manual.

Paint damage Although the FSC cabinet is packed and transported with care, it ispossible that paint is damaged. If any paint damage is detected, touchup these spots before transporting the FSC cabinet to its finallocation. This is the only way to prevent corrosion of the FSCcabinet.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 differentcolors are used.

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, takethe following steps:1. Look for visual damage of the wooden crating.

If the wooden crate is damaged, be aware that the FSC cabinetinside the wooden crate may also be damaged.

2. Remove the top and sides of the wooden crate and look for visualdamage 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 HoneywellSMS has been obtained. Make sure to take pictures of the damagefor insurance purposes.

3. If no damage was found, the FSC cabinet can be removed fromthe wooden pallet and transported to its final location (seesubsections 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 isproperly secured to the pallet, Europallet or wooden beamsfor safety reasons.

• Opening swing frames when FSC cabinets are not properlybolted to the floor might tip over the FSC cabinets resulting insevere damage to the equipment and/or serious injury topeople.

• For safety reasons, do not open more than one swing frame ata time.

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Cardboardwrapping onEuropallet

To unpack an FSC cabinet which is shipped in a cardboard wrappingplaced 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 FSCcabinet inside the wooden crate may also be damaged.

2. Remove the cardboard wrapping and look for visual damage onthe FSC cabinet. If the FSC cabinet is damaged, inform theinsurance company and Honeywell SMS. In any case, do notoperate the equipment until conformation from Honeywell SMShas been obtained. Make sure to take pictures of the damage forinsurance purposes.

3. If no damage was found, the FSC cabinet can be removed fromthe Europallet and transported to its final location (see subsections2.4.2 and 2.4.3 for details).





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Cardboardwrapping onwooden beams

To unpack an FSC cabinet which is shipped in a cardboard wrappingplaced 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 FSCcabinet inside the wooden crate may also be damaged.

2. Remove the cardboard wrapping and look for visual damage onthe FSC cabinet. If the FSC cabinet is damaged, inform theinsurance company and Honeywell SMS. In any case, do notoperate the equipment until conformation from Honeywell SMShas been obtained. Make sure to take pictures of the damage forinsurance purposes.

3. If no damage was found, the FSC cabinet can be removed fromthe wooden beams and transported to its final location (seesubsections 2.4.2 and 2.4.3 for details).The wooden beams are connected to the plinth using M12x80bolts. Use a wrench size 19 to disconnect the wooden beams. Ifthree or four Rittal cabinets are built together as one shippingsection, the wooden beam in the middle is not mounted to theplinth. This beam is only for additional support/clamp duringtransportation and/or storage.





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2.4.2 Moving preparations

Background Several basic points need to be kept in mind when planning themovement 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)

(31½ x 23½ x 78¾ in).PS 4808:Measurements: 80 x 80 x 200 cm (width x depth x height)

(31½ x 31½ x 78¾ 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 orPS 4808 cabinet.

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Checklist Table 2-1 provides a checklist to be used when planning themovement of an FSC cabinet.

Table 2-1 Move preparation checklist

Item Action Notes Check

1 Travel Route 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.

2 Space Is there enough space to hold the equipment?3 Floor loading Will the floor in all areas be strong enough?4 Power distribution Check for proper transformer sizes, distribution panels

and sufficient outlets for support, test andmaintenance equipment.

5 Grounding Be sure that proper grounds are available.6 Conduits and

cable traysMake sure that conduits and cable trays are largeenough and of the proper type to accommodate all ofthe required cables.

7 Environment Are lighting and other environmental requirementsadequate?

8 Security Provide security clearances for the installation crew ifit is not composed of regular employees.

9 Responsibilities Are all responsibilities clearly defined andunderstood?

10 Communications Are telephones and telephones numbers available for:• Operator Emergency, and• Your local Honeywell SMS affiliate

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Preparations Table 2-2 provides a checklist to be used when preparing theelectronics room for an FSC cabinet.

Table 2-2 Preparing the electronics room

Item Action Notes Check

1 Static electricity Reduce the ESD-borne failures by:

• stripping the floors of any wax to prevent staticcharge buildup,

• using anti-static spray on floors, furniture andfabric in the work area, and

• placing a sign on or near the equipment thatstates circuit boards are not to be handled withoutwearing a ground strap.

2 Tack rugs Placed at all entrances, tack rugs catch dust, grit andabrasives from other areas.

3 Fire prevention Consult with the local fire prevention authority toselect fire extinguishers suitable for electrical fires.

4 Room layout Prepare an electronics room layout diagram forcabinet placement.

5 Cabinetbolt-down

Bolt down the FSC cabinet to the floor.(Refer to Appendix A for placement and dimensions ofthe 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 hardwareinstalled and can go as high as 550 kg (1210 lb) per RittalPS 4806 or PS 4808 cabinet.

• Do not tilt the FSC cabinet more than 15º front or back toavoid damage to the doors and/or equipment inside the FSCcabinet.

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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 forklist to move the equipment.

Table 2-3 Fork lift considerations

Number Consideration

1 Move the equipment to the electronics room by fork lift; remove the fork liftby placing the equipment onto the lumber pieces by 10 cm (4 in) asillustrated in Figure 2-1.

2 Tip the cabinet off the lumber and onto the floor; remove the lumber.

3 Manually move the cabinet to the exact final position.

Solid piece or combinationof lumber pieces to match skidor 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 atransport skid made from angle iron. It is then moved with a mobilelifter. Table 2-4 lists special considerations regarding the use of amobile lifter to move the equipment.

Table 2-4 Mobile lift considerations


1 Tilt the equipment slightly and slide one of the angle irons used to make upa transport skid underneath the cabinet as in Figure 2-2.

2 Repeat the above step for the other angle.

3 Insert a strip of heavy cardboard between each angle iron and theequipment finish.

4 Tighten the angle irons against the cabinet by tapping slightly.

5 Insert and tighten two 12 mm (0.5 in) minimum, threaded cross rods as inFigure 2-2 and Figure 2-3.

6 Spread the lifter forks to 80 cm (31½ in) centers and put them under eachcross rod. Place the fork's dowels between the cross rods and the cabinet,just touching the cross rods.

7 Place wooden spacer blocks along the forks, long enough to press thecross rods against the fork dowels.

8 Position a protective plate using braces as shown in Figure 2-2. Be surethat the plate does not press against handles or other cabinet hardware.

9 Raise both lifter forks evenly until the equipment clears the shipping skid;pull it out of the way.

10 Wheel the equipment to the final position in the electronics room; lower it tothe floor.

11 Pull out the mobile lifters. Dismantle and remove the angle iron transportskid.

12 Manually place the cabinet in the exact final position.

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Mobile lifters(continued)

Figure 2-2 shows how the FSC cabinet is to be placed using a mobilelifter.

Wooden brace andprotective plate

Fork dowel

Cross rod

2" x 4"Spacer block

Mobile lifter(2 req'd)

Angle irontransport skid

��

Hydraulicjack

��

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 mobilelifter or crane.

1.25 cm (0.5 in) (minimum)threaded cross rods with nuts Angle iron

support

Spreader

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 cabinetis moved to its final location by placing pipe rollers under a transportskid made of angle iron. Table 2-5 lists special considerationsregarding the use of the roller method to move the equipment.

Table 2-5 Roller method considerations


1 Use one of the previous methods to move the cabinet to a location whererollers are to be used.

2 Install the angle iron transport skid as in the mobile lifter method.

3 Place 12 mm (1/2 inch) pipes under the transport skid as shown in Figure2-4.

ATTENTION The load must be on the angle irons, not the cabinet.

4 Roll the cabinet to its final location.

ATTENTION At least three pipes must be under the transport skid atall times.

5 When the cabinet is near the final location, tilt it and pull out the pipes, themiddle one last.

6 Dismantle the transport skid and position the cabinet manually to the exactfinal location.

2.5 cm (1 in) pipes (minimum)

Angle ironsupports

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. Useeither an angle iron transport skid (see Figure 2-4) or the liftingeyebolts installed on each section of Rittal cabinets (see Figure 2-5).

Onebay

Twobays

Threebays

Fourbays

x x

x x

x

x

x

x

x

x

x

x

x

x

x

x

Figure 2-5 Eyebolt crane method

Leveling anbolt-down

The FSC cabinet does not include levelers. It may be necessary tohand-fit shims underneath the FSC cabinet in order to make thecabinet sit solidly. All FSC cabinets, when arrived at their finallocation, should be bolted to the floor for safety reasons.Opening swing frames when the FSC cabinets are not properly boltedto the floor might tip over the FSC cabinets resulting in severe damageto the equipment and/or serious injury to people.

Appendix A of this Service Manual shows the dimensions andlocations of the bolt-down holes.

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2.4.4 Interconnecting FSC cabinets

InterconnectingFSC cabinets

It is possible that FSC cabinets are shipped in sections, which have tobe bolted together on site. The general drawings of the project-relateddocumentation will always show how the FSC cabinets should beplaced.The side plates should always be mounted during transportation andshipment of the FSC cabinet as these provide extra mechanicalstrength.

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 cabinetstogether. For removing the red swing frame brackets refer tosubsection 2.5.

8. Connect an earth strap, which can be removed from one of theobsolete 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

After placement This subsection lists items that should be checked before proceedingwith the start-up of the FSC cabinet as described in Section 4 of thisService 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.

Swing framebrackets

Red transportation brackets are mounted on each swing frame of theFSC cabinet in order to ensure that the swing frame is not damagedduring transportation. Two brackets are mounted for each swingframe. These should be removed after the FSC cabinet has beenplaced at its final location.

Note:If the FSC cabinet is placed at a temporary location (e.g. toperform an integration test), make sure the red transportationbrackets are mounted again before shipment of the FSC cabinetto its final location in order to avoid damage duringtransportation.

Adjustingthe swing frame

After the FSC cabinet has been placed at its final location, check thatthe swing frame opens smoothly. If it does not, you should adjust themounting kit which secures the swing frame.

Important!Take precautions to prevent that the swing frame will bedismounted from the mounting kit during adjustment of theswing frame. If you do not, a very dangerous situation mayarise which may cause damage to the equipment and/or seriousinjury to persons as the swing frame may be dislocated from themounting kit during adjustment.

Service Manual


Forced ventilation In most FSC cabinets, fans are mounted in the roof and cabinet doorsto 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 dangeroussituations.

• Do not obstruct the filters.If false air enters the FSC cabinet, more dust particles will enter theFSC cabinet and this may result in a malfunction of the equipment.

By default, FSC cabinets have an Ingress Protection (IP) rating ofIP20 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 customerrequirements.

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Section 3: Connection of External Cables 37

Section 3 – Connection of External Cables


Section overview This section provides information on connection of external cables tothe FSC cabinet. It covers the following topics:


3.1 Section overview............................................................................................. 373.2 Interconnection wiring..................................................................................... 383.3 Separation and routing of cables and wiring .................................................. 393.4 Earth/grounding cables................................................................................... 403.4.1 Introduction ..................................................................................................... 403.4.2 Safety earth/ground ........................................................................................ 413.4.3 Instrument earth/ground ................................................................................. 413.4.4 Ex(i) earth/ground ........................................................................................... 413.5 Power/feeder cables ....................................................................................... 423.5.1 Introduction ..................................................................................................... 423.5.2 Supply voltages .............................................................................................. 423.5.3 AC/DC power supply units.............................................................................. 433.5.4 Connecting AC power/feeder cables .............................................................. 433.5.5 DC power ........................................................................................................ 453.5.6 Connecting DC power/feeder cables.............................................................. 453.6 Field cables..................................................................................................... 483.6.1 Introduction ..................................................................................................... 483.6.2 I/O module wiring using FTA-T devices.......................................................... 493.6.3 I/O module wiring using FTA-E....................................................................... 523.6.4 I/O module wiring using terminals .................................................................. 553.6.5 I/O module wiring using third-party devices.................................................... 583.7 Communication cables ................................................................................... 613.7.1 Introduction ..................................................................................................... 613.7.2 Connecting fiber optic cables.......................................................................... 623.7.3 Connecting trunk cables to taps ..................................................................... 663.7.4 Connecting other communication cables........................................................ 66

Installationcompleted

At this point, the installation of the FSC cabinet as described inSection 2 of this Service Manual should have been completedsuccessfully.


It is recommended that a Honeywell SMS representative is presentduring work on the FSC cabinet. This is to ensure that the correctprocedures are being followed. Moreover, should any problems ariseduring the installation, they can be solved on the spot.

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38 Section 3: Connection of External Cables

3.2 Interconnection wiring

Interconnectionwiring

If an FSC cabinet consists of multiple Rittal cabinets, it is possiblethat they will be shipped as separate shipping sections. This can bedue to the total size of the Rittal cabinets, total weight, or customerrequirements.If FSC cabinets are shipped as separate sections, interconnectionwiring between the different shipping sections may need to beinstalled. 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 allwires/cables to be connected between the different sections.Refer to this list for details on the interconnection wiring.

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3.3 Separation and routing of cables and wiring

Separation androuting of cablesand wiring

The wires/cables carrying different voltage levels must be separatedaccording to the principles as shown in Table 3-1 below.

Table 3-1 Routing of cables carrying different voltages

Voltage levelin cable

Requirements

5 Vdc Cables carrying this voltage must always be routedseparately from other voltages.

24 Vdc48 Vdc60 Vdc

Cables carrying these voltages may be routed together.

110 Vdc220 Vdc 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 cablesrunning from FSC communication modules to FSCcommunication 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 anadjacent FSC system cabinet, these cables/wires must beseparated from other cables/wires which need to be routed tothese cabinets.

5. Fiber-optic cables may be routed with other cables, but theyshould be routed in such a way that they are not exposed tophysical 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 fourdifferent 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 ofcables 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 thatthe 0 Vdc of the voltages used in the FSC cabinet are not connected toan earth/ground bar and/or earth/ground point.

The cables from the safety earth/ground bar and instrumentearth/ground bar can be connected together to the safety earth rod ofthe plant.

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3.4.2 Safety earth/ground

Safety earth/ground Each FSC cabinet is equipped with a safety earth/ground bar, whichis 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 tothe safety earth/ground bolt, which is available in the FSC cabinet.

Note:The safety earth/ground and instrument earth/ground can beconnected together at one and one point only.

3.4.3 Instrument earth/ground

Instrumentearth/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 beconnected together at one and one point only.

3.4.4 Ex(i) earth/ground

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+Fuchsequipment as mentioned in subsection 3.6 of this Service Manual.A separate earth rod will be installed for the Ex(i) earth/ground.

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3.5 Power/feeder cables

3.5.1 Introduction

Cable types The cables that enter the FSC cabinet can be divided into fourdifferent 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).


3.5.2 Supply voltages

Voltage types The power/feeder cables supply the FSC cabinet with the variousvoltages 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 systemand the customer requirements. However, 24 Vdc is always requiredby the FSC system hardware. The 24 Vdc is normally generated bypower supply units (PSUs) mounted in the FSC cabinet.

The power/feeder cables for AC voltages will be connected to fuseterminals or a main circuit breaker (see subsection 3.5.4).The power/feeder cables for DC voltages will be connected to fuseterminals, a main circuit breaker or a power distribution rail (seesubsection 3.5.6).

High voltages Equipment with high voltages (i.e. above 40 Vdc or 30 Vac) arecovered by a protective plate or cover. If these voltages areconnected, take extra precautions when the protective plates/coversare removed.After connecting the power/feeder cables, make sure that you put theprotective plates/covers back into place.

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3.5.3 AC/DC power supply units

AC/DC powersupply units

Only TÜV-approved power supply units (PSUs) may be used inconjunction with the FSC system. The following power supply unitsare currently TÜV 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 requirementsrefer to the FSC Hardware Manual.

Note:If the incoming AC power/feeder cables do not meet therequirements as mentioned in the data sheets of the powersupply units (PSUs), the FSC system should not be operated.

3.5.4 Connecting AC power/feeder cables

Connecting ACpower/feeder cables

The procedure below describes the steps to be taken to connect theAC 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 followingitems 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 (whichprovides the AC power to the FSC cabinet) is switched off.

2. Remove the protective plate/cover from the main circuit breakerand/or fuse terminals inside the FSC cabinet.

3. Connect the AC power/feeder cable to the corresponding maincircuit breaker and/or fuse terminals installed in the FSC cabinet.For detailed information on which cable should be connected referto the power distribution drawings, which are part of theproject-related documentation.For detailed information on the exact location of the main circuitbreaker and/or fuse terminals refer to the general drawings, whichare part of the project-related documentation.

4. Measure the resistance between earth of the FSC cabinet frameand the earth connection of the AC power/feeder cable. Theresistance should be ≤ 0.1 Ohm. If the resistance is higher, thecause should be identified and solved before continuing theconnection of AC power/feeder cables.

5. Place the required ferrites on each AC power/feeder cable (if notalready installed in the FSC cabinet). For detailed information onferrites 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 fuseterminals as high voltages will damage the equipment ofthe FSC cabinet.

b) If the incoming AC power/feeder does not meet therequirements as mentioned in the data sheets of thepower supply units (PSUs), the FSC system should notbe operated.

c) Pay close attention to the requirements as described insubsection 3.3 with respect to separation and routing ofcables and wiring.

6. Switch on the main breakers in the AC distribution panel, andmeasure the incoming AC voltage on the main circuit breakerand/or fuse terminals installed in the FSC cabinet.

7. After measuring the AC voltage, switch off the circuit breaker inthe AC distribution board.

8. Put the protective plate/cover from the main circuit breaker and/orfuse terminals in the FSC cabinet back into place.

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3.5.5 DC power

DC power If DC voltages are supplied to the FSC cabinet, these should bewithin the following range to ensure correct operation of the FSCsystem:• 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 to25 Vdc (identical to the approved Delta power supply units suppliedby HSMS). This is to ensure that the voltage at the modules willalways be in accordance with requirements, taking into account thevoltage drop in the FSC cabinet.

Note:If the incoming DC power/feeders cables do not meet therequirements mentioned above, the FSC system should not beoperated.

3.5.6 Connecting DC power/feeder cables

Connecting DCpower/feeder cables

The procedure below discusses the steps to be taken to connect theDC 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 followingitems 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 DC power/feeder cable, check that the

circuit breaker mounted in the DC distribution panel (whichprovides the DC power to the FSC cabinet) is switched off.

2. Remove the protective plate/cover from the main circuit breakerand/or fuse terminals inside the FSC cabinet.

3. Connect the DC power/feeder cable to the corresponding maincircuit breaker, fuse terminals and/or power distribution railsinstalled in the FSC cabinet.For detailed information on which cable should be connected referto the power distribution drawings, which are part of the project-related documentation.For detailed information on the exact location of the main circuitbreaker, fuse terminals and/or power distribution rails refer to thegeneral drawings, which are part of the project-relateddocumentation.

4. Measure the resistance between earth of the FSC cabinet frameand the earth connection of the DC power/feeder cable. Theresistance should be ≤ 0.1 Ohm. If the resistance is higher, thecause should be identified and solved before continuing theconnection of DC power/feeder cables.

5. Place the required ferrites on each DC power/feeder cable (if notalready installed in the FSC cabinet). For detailed information onferrites 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 fuseterminals as high voltages will damage the equipment ofthe FSC cabinet.

b) If the incoming AC power/feeder does not meet therequirements as mentioned in the data sheets of thepower supply units (PSUs), the FSC system should notbe operated.

c) Pay close attention to the requirements as described insubsection 3.3 with respect to separation and routing ofcables and wiring.

6. Switch on the main breakers in the DC distribution panel, andmeasure the incoming DC voltage on the main circuit breaker,fuse terminals and/or power distribution rails installed in the FSCcabinet.

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7. After measuring the DC voltage, switch off the circuit breaker inthe DC distribution board.

8. Put the protective plate/cover from the main circuit breaker, fuseterminals and/or power distribution rails in the FSC cabinet backinto 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 fourdifferent 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 forinterconnection between the FSC cabinets and other equipment, forexample marshalling cabinets and/or local panels.Details on the requirements with regard to separation and routing ofcables 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, theseconnections 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 thefollowing 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 withscrew terminals to connect field wires directly. They are electricallypassive devices which simply pass incoming or outgoing signalsbetween the field and I/O modules. Figure 3-1 below illustrates atypical routing layout of the internal wiring between I/O modules andFTA-T via system interconnection cables (SIC-Cs).

FTA connector

System I/O cable

I/O module

I/O module connector

Backplane FTA-T

Terminal block

Figure 3-1 Typical routing of internal wiring between I/O modulesand FTA-T via SIC-Cs

Connecting FTA-T Fields cables are used for interconnection between FTA-Ts and otherequipment, e.g. marshalling cabinets and/or local panels. The FTA-Tsneed not necessarily be placed in the FSC cabinet. They can also beplaced remotely (e.g. a marshalling cabinet).

Before connecting the field cables, take the following steps to preventdamage 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 thecores to avoid tension on the connections on the FTA-Ts.

4. If required, connect the earth wire from the field cable to theFTA-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 fusesback into the fuse terminals or FTA-Ts as long as no poweris applied to all systems and not all signals have beenchecked for high voltages and short circuiting which may becaused by wiring faults in the field and/or junction boxes.These high voltages will damage the equipment of the FSCcabinet. The voltages and short circuiting need to bechecked on the external devices.

6. Close all knife-type terminals and put the fuses back into theterminals used for the I/O wiring and the FTAs.

The next steps are only applicable to field cables carrying signalswhich are connected via FTA-Ts to the following type of FSC I/Omodules:• 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 tothe general drawings, which are part of the project-relateddocumentation.For detailed information on the FSC I/O modules connected to theFTA-Ts via SIC-Cs, refer to the termination details, which are part ofthe project-related documentation.

Note:Pay close attention to the requirements as described insubsection 3.3 with respect to separation and routing of cablesand wiring.

FTA-Tmaximum wirediameter

For detailed information on the maximum wire diameter refer to thedata sheet of the applicable FTA-T module in the FSC HardwareManual.

FTA-Twire strip length

For detailed information on the wire strip length refer to the datasheet of the applicable FTA-T module in the FSC Hardware Manual.

FTA-Ttightening torque

For detailed information on the tightening torque refer to the datasheet 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 astandard Elco E-56 connector to connect E-56 system cables. Theyare electrically passive devices which simply pass incoming oroutgoing signals between the field and I/O modules.Figure 3-3 below illustrates a typical routing layout of the internalwiring between I/O modules and FTA-E via system interconnectioncables (SIC-Cs).

FTA connector

System I/O cable

I/O module

I/O module connector

Backplane FTA-E

Elco 56/54-pin (E56) connector

Figure 3-3 Typical routing of internal wiring between I/O modulesand FTA-E via SIC-Cs

Connecting FTA-E System cables (Elco cables) are used for interconnection betweenFTA-Es and other equipment, e.g. a DCS system and/or marshallingcabinets.The FTA-Es need not necessarily be placed in the FSC cabinet. Theycan 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 forconnection to screw terminals.

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Before connecting the system cables, take the following steps toprevent damage to the FSC equipment:• Open all knife-type terminals installed in the FSC cabinet and/or


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 allowconnection of the system cable plug to the FTA-E. Do not connectthe 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 fuseterminals or FTA-Es as long as no power is applied to allsystems and not all signals have been checked for highvoltages and short circuiting which may be caused bywiring faults in the field and/or junction boxes.These high voltages will damage the equipment of the FSCcabinet. The voltages and short circuiting need to bechecked on the external devices.

7. Connect the system cable connector to the FTA-E mounted in theFSC cabinet, close all knife-type terminals, and place back thefuses 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 signalswhich are connected via FTA-Es to the following type of FSC I/Omodules:• 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).


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 tothe general drawings, which are part of the project-relateddocumentation.For detailed information on the FSC I/O modules connected to theFTA-Es via SIC-Cs, refer to the termination details, which are part ofthe project-related documentation.


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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 wiringbetween I/O modules and terminals via system interconnection cableswith crimp pins (SIC-Ps).

Crimp pins

I/O module connector (a)

I/O module connector (b)

System interconnection cable

Figure 3-5 Typical layout of a SIC-P cable

Connectingterminals

Fields cables are used for interconnection between terminals placedin the FSC cabinet and other equipment, e.g. marshalling cabinetsand/or local panels. The terminals need not necessarily be placed inthe FSC cabinet. They can also be placed remotely (e.g. a marshallingcabinet).

Before connecting the SIC-P and field cables, take the following stepsto prevent damage to the FSC equipment:• Open all knife-type terminals installed in the FSC cabinet and/or


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 arepart of the project-related documentation. Leave sufficient slackon the cores to avoid tension on the connections on the terminals.


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 toavoid tension on the connections on the terminals.


Note:Do not close any knife-type terminals or place the fusesback into the fuse terminals as long as no power is appliedto all systems and not all signals have been checked for highvoltages and short circuiting which may be caused bywiring faults in the field and/or junction boxes.These high voltages will damage the equipment of the FSCcabinet. The voltages and short circuiting need to bechecked on the external devices.

5. Close all knife-type terminals and place back the fuses in theterminals used for the I/O wiring and the FTAs.

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The next steps are only applicable to field cables carrying signalswhich are connected via FTA-Ts to the following type of FSC I/Omodules:• 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).


Cable clamps

Cable clamp rails

Figure 3-6 Bonding of shielded cables (terminals)

For detailed information on the exact location of the terminals refer tothe general drawings, which are part of the project-relateddocumentation.For detailed information on the FSC I/O modules connected to theterminals via SIC-Cs, refer to the termination details, which are part ofthe project-related documentation.


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Terminalmaximum wirediameter

For detailed information on the maximum wire diameter refer to thedata sheets of the applicable terminals.

Terminalwire strip length

For detailed information on the wire strip length refer to the datasheets of the applicable terminals.

Terminaltightening torque

For detailed information on the tightening torque refer to the datasheets of the applicable terminals.

3.6.5 I/O module wiring using third-party devices

Usingthird-party devices

Two manufactures currently provide devices (backplanes) which canbe 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/Omodules and:• Ex(i) field devices.

In this case all field cables should be colored blue and the fieldcables 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.


Connectingthird-party devices

Fields cables are used for interconnection between the third-partydevices placed in the FSC cabinet and other equipment, e.g.marshalling cabinets and/or local panels. The third-party devices neednot necessarily be placed in the FSC cabinet. They can also be placedremotely (e.g. a marshalling cabinet).

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Before connecting the field cables, take the following steps to preventdamage to the FSC equipment:• Open all knife-type terminals installed in the FSC cabinet and/or


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 sufficientslack on the cores to avoid tension on the connections on theterminals on the third-party device. Special field connectors maybe required, depending on the manufacturer.


Note:Do not close any knife-type terminals or place the fusesback into the fuse terminals as long as no power is appliedto all systems and not all signals have been checked for highvoltages and short circuiting which may be caused bywiring faults in the field and/or junction boxes.These high voltages will damage the equipment of the FSCcabinet. The voltages and short circuiting need to bechecked on the external devices.

5. Close all knife-type terminals and place back the fuses in theterminals used for the I/O wiring.

For detailed information on the exact location of the third-partydevices refer to the general drawings, which are part of theproject-related documentation.For detailed information on the FSC I/O modules connected to thethird-party devices refer to the termination details, which are part ofthe project-related documentation.


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Terminalsmaximum wirediameter

For detailed information on the maximum wire diameter refer to thedata sheets of the applicable third-party device.

Terminalwire strip length

For detailed information on the wire strip length refer to the datasheets of the applicable third-party device.

Terminaltightening torque

For detailed information on the tightening torque refer to the datasheets 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 fourdifferent 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).


Overview The communication modules of the FSC system are placed in theCentral Part(s).The communication interface boards of the FSC system are placed inthe FSC cabinet. This is done in order to achieve easy access to theFSC cabinet for the external communication cables. Thecommunication interface boards can be considered an extension of thecommunication modules. Taps are mounted in the FSC cabinet for theFSC-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 detailin the following subsections.

For detailed information on which cables should be connected refer tothe communication drawings, which are part of the project-relateddocumentation.For detailed information on the exact location of the taps andcommunication modules/interfaces refer to the general drawings,which are part of the project-related documentation.

3.7.2 Connecting fiber optic cables

Connecting fiberoptic 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 modulesin 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 arerouted via the horizontal bus (H-Bus) mounted above the CentralPart(s).

2. Clamp the fiber optic cable to the cable tray or cable ductmounted on the left-hand side of the FSC cabinet. Pay closeattention 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 withouttension on the cables.

− Check the specification of the fiber optic cable for the minimumbend 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 communicationmodules placed in the Central Part(s) refer to the rack layouts, whichare part of the project-related documentation.For detailed information on the exact location of the fiber opticconverter refer to the general drawings, which are part of the project-related documentation.

Considerations If the fiber optic cables are to be connected to the communicationmodules placed in the Central Part(s), the following considerationsshould 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 onthe left hand side of the FSC cabinet.

• Check the specification of the fiber optic cable for the minimumbend radius. Make sure that the fiber optic cable can be routed insuch a way that the bend radius in the cable will never be less thanthe specified minimum.

• Check the maximum allowable transmission loss. This is 23.5 dBfor fiber optic communication between G interfaces mounted in theCentral Parts.

• Check the minimum required transmission loss. This is 8 dB forfiber optic communication between G interfaces. To achieve theminimum required transmission loss, fiber optic dampers may needto be installed.


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Fiber opticconverter module

To connect the fiber optic cables to the fiber optic converter modulemounted 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 FSCcabinet. 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 opticconverter refer to the general drawings, which are part of the project-related documentation.

Considerations If the fiber optic cables are to be connected to a fiber optic converterplaced in the FSC cabinet, the following considerations should benoted:• 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 insuch a way that the bend radius in the cable will never be less thanthe 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 needto be installed.


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Splice panel To connect the fiber optic cables to a splice panel mounted in theFSC 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 arerouted via the horizontal bus (H-Bus) mounted above the CentralPart(s).

2. Clamp the fiber optic cable to the cable tray or cable ductmounted on the left-hand side of the FSC cabinet. Pay closeattention 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 withouttension on the cables.

− Check the specification of the fiber optic cable for the minimumbend diameter.

3. Roll the fiber optic cable to the splice panel mounted in the FSCcabinet.

4. Clamp the fiber optic cable to the cable tray or cable ductmounted next to the splice panel in the FSC cabinet. Pay closeattention 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 theconnections.

For detailed information on the exact location of the communicationmodules placed in the Central Part(s) refer to the rack layouts, whichare part of the project-related documentation.For detailed information on the exact location of the splice panel referto the general drawings, which are part of the project-relateddocumentation.

Please note that the transmitter signal and receive signal between twodevices that use communication via fiber optic cables should beswapped.


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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 withthe correct torque. If you do not use a torque wrench, this might resultin damaged cables and/or modules.

For detailed information on which cables should be connected refer tothe communication drawings, which are part of the project-relateddocumentation.For detailed information on the exact location of the taps refer to thegeneral drawings, which are part of the project-related documentation.


3.7.4 Connecting other communication cables

Connecting othercommunicationcables To connect the other communication cables, take the following steps:

1. Connect the plug to the corresponding communication modulelocated in the FSC cabinet.

2. Fasten the screws of the cable connector to the communicationmodule.

3. Clamp the communication cable to the cable tray or duct mountednext to the communication module using tire wraps. Pay closeattention 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 thecorresponding device.

6. Fasten the screw of the cable connector to connector in thecorresponding device.

For detailed information on which cables should be connected refer tothe communication drawings, which are part of the project-relateddocumentation.For detailed information on the exact location of the communicationmodules refer to the general drawings, which are part of the project-related documentation.


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Section 4: Power-Up of the FSC Cabinet 69

Section 4 – Power-Up of the FSC Cabinet


Section overview This section provides information on powering up the FSC cabinet.It covers the following topics:


4.1 Section overview............................................................................................. 694.2 Checks prior to power-up................................................................................ 704.2.1 Checking all signal wiring ............................................................................... 704.2.2 Checking all incoming power .......................................................................... 704.2.3 Checking AC power ........................................................................................ 704.2.4 Checking DC power........................................................................................ 724.3 Performing the power-up ................................................................................ 734.3.1 Powering up a redundant system ................................................................... 734.3.2 Powering up a single system.......................................................................... 734.3.3 Troubleshooting .............................................................................................. 734.3.4 Activities after power-up ................................................................................. 74


It is recommended that the power-up of the FSC system is monitoredby a Honeywell SMS representative who is familiar with the FSCsystem. This is to ensure that the correct procedures are beingfollowed. Moreover, should any problems arise during theinstallation, they can be solved on the spot.

Procedure 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.

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70 Section 4: Power-Up of the FSC Cabinet

4.2 Checks prior to power-up

4.2.1 Checking all signal wiring

Checking allsignal wiring

Check all signal wiring to and from the FSC cabinet for high voltagelevels and short circuiting (for outputs) as they may damage theelectronic equipment of the FSC system.

Checking all signal wiring can be skipped if this subsection isperformed directly after connecting and checking the cables to theFSC system as described in Section 3 of this manual.

4.2.2 Checking all incoming power

Checking allincoming power

Before the power-up of the FSC system, all power supply unitsand/or external power supplied to the FSC cabinet need to beactivated.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 fuseterminals and/or main circuit breaker in accordance with subsection3.5.4 of this manual.

Before starting the test of the PSUs, check the following items in theFSC 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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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 asmentioned in the data sheets of the power supply units(PSUs), the FSC system should not be operated.

4. Switch on the secondary disconnector of the PSU.5. Switch on the main circuit breaker of the PSU.6. Check the LED on the PSU (it should be on).7. 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 circuitbreaker rack refer to the general drawings, which are part of theproject-related documentation.

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4.2.4 Checking DC power

DC power In order to ensure that all required external power is available, thisneeds to be tested individually for each feeder.The DC power/feeder cables should have been connected to the fuseterminals and/or main circuit breaker in accordance with subsection3.5.6 of this manual.

Before starting the test of the external power supply, check thefollowing 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 theFSC 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 asmentioned in subsection 3.5.5 of this manual, the FSCsystem should not be operated.

3. Place the fuses in the fuse terminals and/or switch on the maincircuit breaker.

4. Using a multimeter, measure the voltage on the main busbar orcircuit breaker rack.

5. Remove the fuses from the fuse terminals and/or switch off themain circuit breaker.

6. Place the required ferrites on each DC power/feeder cable (if notalready installed in the FSC cabinet). For detailed information onferrites 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 generaldrawings, which are part of the project-related documentation.

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4.3 Performing the power-up

4.3.1 Powering up a redundant system

Powering up aredundant system


The power-up of an FSC system with redundant Central Parts mustbe performed in accordance with the procedure as described inAppendix C of this Service Manual.

4.3.2 Powering up a single system

Powering up asingle system


The power-up of an FSC system with a single Central Part mustbe performed in accordance with the procedure as described inAppendix C of this Service Manual.

4.3.3 Troubleshooting

Troubleshooting It is possible that alarm/error messages are generated during thepower-up of the FSC system. For an explanation of the most commonalarms/error generated during the power-up of the FSC system referto Appendix D of this manual.For more information on the alarms/error messages generated by theFSC 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 preventivemaintenance tasks should always be carried out. For details refer toSection 7 of this Service Manual.

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Section 5: Site Acceptance Test 75

Section 5 – Site Acceptance Test


Section overview This section provides general information on the Site AcceptanceTest (SAT) to be performed on the FSC cabinet.


5.1 Section overview............................................................................................. 755.2 SAT definition and objective ........................................................................... 765.3 Involved parties............................................................................................... 775.4 Documentation required ................................................................................. 775.5 Contents of the SAT document ...................................................................... 79

Start At this point, the power-up of the FSC cabinet as described inSection 4 of this manual should have been completed successfully.

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76 Section 5: Site Acceptance Test

5.2 SAT definition and objective

SAT The Site Acceptance Test (SAT) is a test that may be performed afterthe FSC cabinet has been transported to site, installed and poweredup. The aim of the SAT is to show to the customer/end user that thedelivered FSC cabinet is operational and in good condition.HSMS has a standard SAT document which can be used as a referencedocument during the SAT.

During the SAT, the FSC cabinet will be checked for several items,including any outstanding issues mentioned in the Factory AcceptanceTest (FAT) document (only if an FAT was performed).

Once the customer/end used has accepted the FSC cabinet by signingthe 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 forthe official acceptance of the FSC cabinet after the SAT.

It is possible that an SAT is not requested by the customer/end user. Inthat case the signing of the release note attached to the FAT documentis the official acceptance by the customer/end user. Here, too, it ispossible that customers/end users have their own release note for theofficial acceptance of the FSC cabinet after the FAT.

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5.3 Involved parties

Who should beinvolved?

As a minimum, the following representatives should be involved toperform 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.

5.4 Documentation required

Documentation The documentation required for the SAT on the FSC system can besplit into two sections:• Project-related documentation, and• FSC user documentation.

Each of these sections is discussed in more detail below.

Project-relateddocumentation

Every FSC cabinet is supplied with project-related documentationwhich provides detailed information and guidelines for the specificFSC cabinet(s). The following information may be included for acabinet:• 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 ormore specific FSC cabinets.

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Note:Always make sure that the latest versions of the project-relateddocumentation is available. This is not necessarily the "as-built"documentation.If you work with old and/or obsolete documentation, this maylead to problems and/or delays during maintenance, service andmodification.

FSC userdocumentation

There is also generic user documentation that applies to all FSCsystems. This documentation provides technical details of the FSChardware 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 technicalspecifications of the FSC hardware modules and components.

• FSC Software Manual.This is the user manual to the FSC Navigator software, which isused to interface with the FSC system.

• FSC Safety Manual.This is a document which provides general information on safetyand safety-related systems, as well as implementation guidelines forFSC systems.

• FSC-SM documentation set.This is a set of manuals that provide information and guidelines forthe 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 thisdocument.

2. All references in this Service Manual made to the FSCSoftware Manual refer to Release 510 and higher.

3. All references in this Service Manual made to the FSCSafety Manual refer to Release 510 and higher.

4. All references in this Service Manual made to the FSC-SMdocumentation refer to the latest version of thisdocumentation.

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5.5 Contents of the SAT document

SAT document HSMS has a standard SAT document which can be used as areference document during the SAT.During the SAT, the items mentioned in this document should bechecked 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 checksmentioned above or in the standard HSMS SAT document.

Obtaining the SATdocument

For information on how to obtain the standard HSMS SAT documentyou can contact your local Honeywell representative.

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Section 6: General Maintenance Considerations 81

Section 6 – General Maintenance Considerations


Section overview This section provides general information on maintenance tasks thatmay need to be performed on the FSC cabinets. It covers thefollowing topics:


6.1 Section overview............................................................................................. 816.2 Types of maintenance .................................................................................... 826.3 Corrective maintenance.................................................................................. 836.4 Actions before maintenance, service and modification .................................. 846.5 Actions during maintenance, service and modification .................................. 866.6 Actions after maintenance, service and modification ..................................... 87

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82 Section 6: General Maintenance Considerations

6.2 Types of maintenance

Maintenance types Maintenance performed on the FSC cabinet can be split into fourmain 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).

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6.3 Corrective maintenance

Correctivemaintenance

Corrective maintenance must be performed after the FSC system hasgenerated an alarm or detected an error. Depending on the alarm orerror reported, certain modules may need to be replaced. Thereplacement procedures for all FSC modules are described in theFSC Maintenance & Replacement Guide (document FS99-505).Contact your local Honeywell representative for details on how toobtain this document.

Important!An alarm/error message generated by the FSC system requiresimmediate attention and action. Ignoring an FSC alarm/errormessage may cause severe damage to the equipment and/orserious injury to people.

Important!Replacement of any equipment inside the FSC cabinet must becarried out with the utmost care, and by authorized andqualified persons only. In case of errors or mistakes during thereplacement of certain modules, the FSC system can go to asafe state resulting in a process shutdown.

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6.4 Actions before maintenance, service and modification

Before workon FSC cabinet

Depending on the tasks to be performed on the FSC cabinet, anumber of actions need to be taken before any maintenance, serviceor modification to the FSC cabinet is carried out. These actions arerequired to ensure that the work on the FSC cabinet is performedwithout any problems and within the given time frame. These actionsmay 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 HoneywellSMS. Where applicable, customer/plant procedures mayoverride them or demand additional actions.

Checkingspare parts

Make sure that the spare modules are of the correct type. This can bechecked by verifying the module numbers and, where applicable,suffix numbers. This information can be found at the front of eachmodule.If the module number and/or suffix number of the spare module do notmatch, do NOT proceed with the replacement of the faulty module.

Note:It is essential that the availability of spare parts is checked on aregular basis to avoid any problems when they are urgentlyneeded. 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 FSCcabinet, 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),• 3½-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.).

Contactingthe operator

Make sure that the operator is contacted before the start of anymaintenance, service and modification.The operator will be able to determine if it acceptable to perform themaintenance, service and modification at that point in time.

Organizingother parties

Assistance from any other parties may be required during themaintenance, service and modification to FSC cabinets. Make surethat all parties required are contacted and that all arrangements aremade.

Permits Make sure that all permits required to perform the maintenance,service and modification to the FSC cabinet are available and signedby the appropriate responsible parties.

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6.5 Actions during maintenance, service and modification

During workon FSC cabinet

Depending on the tasks to be performed on the FSC cabinet, anumber of actions need to be taken while maintenance, service ormodification to the FSC cabinet is being carried out. These actionsare required to ensure that the work on the FSC cabinet is performedwithout any problems and within the given time frame. These actionsmay include (but need not be limited to):• Contacting the operator, and• Contacting other parties (if any).




Make sure that the operator is kept informed on the progress of themaintenance, service and modification work performed.

Contactingother parties

Make sure that any other parties involved are kept informed on theprogress of the maintenance, service and modification workperformed.

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6.6 Actions after maintenance, service and modification

After workon FSC cabinet

Depending on the tasks to be performed on the FSC cabinet, anumber of actions need to be taken after any maintenance, service ormodification to the FSC cabinet has been carried out. These actionsare required to ensure that the work on the FSC cabinet is performedwithout any problems and within the given time frame. These actionsmay include (but need not be limited to):• Contacting the operator,• Taking care of permits, and• Making sure that defective items are repaired.




Make sure that the operator is informed that the maintenance, serviceand modification has been completed successfully.

Permits Make sure that all permits that were required to perform themaintenance, service and modification are signed and returned to theappropriate responsible parties.

Repair defect items If during maintenance, service and modification items have beenreplaced of removed from the FSC cabinet, these need to be checkedfor their functionality. For the FSC Central Part and I/O modules thiscan be done using an FSC simulation/training unit.

If any items are found to be defective, they can be returned to HSMSfor further investigation into the cost of repair. For details on how toreturn defective items refer to Appendix G of this Service Manual.

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Section 7: Preventive Maintenance 89

Section 7 – Preventive Maintenance


Section overview This section provides information on the preventive maintenance thatneeds to be performed regularly on the FSC cabinets. It covers thefollowing topics:


7.1 Section overview............................................................................................. 897.2 Preventive maintenance overview.................................................................. 907.3 Three-monthly preventive maintenance ......................................................... 917.3.1 Overview......................................................................................................... 917.3.2 Checking the voltages to the Central Part ...................................................... 917.3.3 Checking the temperatures in the Central Part .............................................. 967.3.4 Checking air flow obstruction.......................................................................... 987.3.5 Checking the correct operation of the fans..................................................... 987.3.6 Checking for earth faults................................................................................. 997.3.7 Checking the loop status of signals .............................................................. 1017.3.8 Checking the forced status of signals........................................................... 1037.3.9 Checking for paint damage........................................................................... 1047.3.10 Checking the availability of spare parts ........................................................ 1047.3.11 Checking the system diagnostics ................................................................. 1057.3.12 Checking the backup of the application files ................................................ 1067.4 Preventive maintenance during every power-down ..................................... 1077.4.1 Overview....................................................................................................... 1077.4.2 Checking all DC voltages.............................................................................. 1087.4.3 Checking the power distribution fuses.......................................................... 1097.4.4 Checking the AC voltages ............................................................................ 1107.4.5 Checking the correct operation of the PSUs ................................................ 1117.4.6 Checking for dust concentration ................................................................... 1127.4.7 Replacing all dust filters................................................................................ 1127.4.8 Checking the fasteners on the power distribution rails................................. 1137.4.9 Checking all cable clamps ............................................................................ 1137.4.10 Checking all shield connections ................................................................... 1147.4.11 Checking all earth/ground connections ........................................................ 1157.4.12 Testing all hardware I/O................................................................................ 1167.4.13 Testing all communication links to external devices..................................... 118

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90 Section 7: Preventive Maintenance

7.2 Preventive maintenance overview

Preventivemaintenance

Preventive maintenance is necessary to prevent faults in the FSCcabinet. It is concentrated on the most sensitive elements in the FSCcabinet. The preventive maintenance that should be carried out can besplit into two major components:• Three-monthly preventive maintenance (see subsection 7.3), and• Preventive maintenance during every power-down (see subsection

7.4).

Checklists Refer to Appendix E for checklists on the items to be performedduring preventive maintenance. This allows you to keep a record andretrieve 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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7.3 Three-monthly preventive maintenance

7.3.1 Overview

Everythree months

The following maintenance items need to be performed every threemonths:• 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).

7.3.2 Checking the voltages to the Central Part

Voltages onthe 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 to5 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 canbe 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 Moduleand the 10300/x/x DC/DC converter refer to the FSC HardwareManual.

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For details on the module locations in the Central Part racks refer tothe rack layout drawings, which are part of the project-relateddocumentation.

Checkingvia 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 from10300/x/x

The voltage generated by the 10300/x/x DC/DC converter should bewithin 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 thefollowing 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 inthe rack can be obtained from the rack layout drawings, which arepart 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 bythe 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 berecalibrated. This requires the 10300/x/x module to be returned toHoneywell SMS. (Refer to Appendix G of this Service Manual fordetails on how to proceed.)

4. You can return to the default display (current time) by moving theDBM switch downward four times. Alternatively, you can waitfor about 30 seconds. The display will then automatically return tothe time display.

The above check needs to be performed for each Central Part in theFSC cabinet.

DBM battery voltage Batteries are mounted on the 10006/x/x Diagnostic and BatteryModule (DBM) which provide the backup power for the RAMmemory on the Central Processing Unit (CPU) and communication(COM) modules.If the FSC system is running in RAM mode and the 24 Vdc to theCentral Part is disconnected, these batteries will ensure that theinformation stored in the RAM chips is retained.When fully charged, the batteries provide sufficient power to ensurethat the data in the RAM chips is retained for three months.

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Note:If the cabinet temperature exceeds 50°C (122°F) for an extendedtime period (>24 hours), the batteries may be damaged and losetheir power backup capabilities.

When a new DBM is supplied, a jumper needs to be set before thebatteries are actually charged. For details on the jumper setting of theDBM module refer to the module data sheet in the FSC HardwareManual.

To check the voltage of the batteries mounted on the DBM, take thefollowing steps:1. A 10006/x/x Diagnostic and Battery Module (DBM) is placed in


2. Push the switch on the DBM upward five times.The display of the DBM will now show the charge voltage levelof 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. Fordetailed information on how to replace the batteries refer to theDBM data sheets in the FSC Hardware Manual.DBM modules with a suffix code lower than 08802 do not haveexchangeable batteries. Should the batteries of these modules needto be replaced, the DBM module must be returned to HoneywellSMS. (Refer to Appendix G of this Service Manual for details onhow to proceed.)

4. You can return to the default display (current time) by moving theDBM switch downward five times. Alternatively, you can wait forabout 30 seconds. The display will then automatically return to thetime display.


Note:It is recommended that the batteries mounted on the DBMmodule are replaced every four years. For details on how toreplace the batteries refer to the DBM data sheet in the FSCHardware Manual.

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Checkingvia FSC Navigator

The following information can be retrieved when using the FSCNavigator 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 inthe FSC cabinet.)

The screen as shown in Figure 7-1 below will appear.This screen is for information purposes only. You cannot editanything in this screen. The information displayed is updatedcontinuously.

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 thanthe voltage generated by the 10300/x/x DC/DC converter. This is dueto the diode on the rear of the S-Bus. If the difference is minimal, thisindicates that the diode on the rear of the S-Bus has failed.

Battery voltageof DBM

Batteries are mounted on the 10006/x/x Diagnostic and BatteryModule (DBM) which provide the backup power for the RAMmemory on the Central Processing Unit (CPU) and communication(COM) modules.If the FSC system is running in RAM mode and the 24 Vdc to theCentral Part is disconnected, these batteries will ensure that theinformation stored in the RAM chips is retained.When fully charged, the batteries provide sufficient power to ensurethat the data in the RAM chips is retained for three months.

Note:If the cabinet temperature exceeds 50°C (122°F) for an extendedtime period (>24 hours), the batteries may be damaged and losetheir power backup capabilities.

When a new DBM is supplied, a jumper needs to be set before thebatteries are actually charged. For details on the jumper setting of theDBM module refer to the module data sheet in the FSC HardwareManual.

The voltage displayed should be higher than 4.05 Vdc.If it is not, the batteries on the DBM should be replaced. For detailedinformation on how to replace the batteries refer to the DBM datasheets in the FSC Hardware Manual.DBM modules with a suffix code lower than 08802 do not haveexchangeable batteries. Should the batteries of these modules need tobe replaced, the DBM module must be returned to Honeywell SMS.(Refer to Appendix G of this Service Manual for details on how toproceed.)

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 tothe rack layout drawings, which are part of the project-relateddocumentation.

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Note:It is recommended that the batteries mounted on the DBMmodule are replaced every four years. For details on how toreplace the batteries refer to the DBM data sheet in the FSCHardware Manual.

Supply voltage from10300/x/x

The voltage generated by the 10300/x/x DC/DC converter should bebetween 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 thenneed to be recalibrated. This requires the 10300/x/x module to bereturned to Honeywell SMS. (Refer to Appendix G of this ServiceManual for details on how to proceed.)

7.3.3 Checking the temperatures in the Central Part

Temperatures inthe Central Parts

Temperature sensors are mounted on the Diagnostic and BatteryModules (DBM HSMS type 10006/x/x) which allow the temperaturesin the Central Part to be monitored.The following temperature setting are specified during the systemconfiguration 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 lowtemperature alarm setpoint or exceeds the high temperature alarmsetpoint, an alarm will be generated.If the temperature detected by the DBM sensors goes below the lowtemperature shutdown setpoint or exceeds the high temperatureshutdown setpoint, the affected Central Part of the FSC system willautomatically stop.

The temperature sensors mounted in the DBM can be checked ineither 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 Moduleand the 10300/x/x DC/DC converter refer to the FSC HardwareManual.

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For details on the module locations in the Central Part racks refer tothe rack layout drawings, which are part of the project-relateddocumentation.

Checkingvia the DBM

To check the temperature sensors in the FSC cabinet, take thefollowing steps:1. A 10006/x/x Diagnostic and Battery Module (DBM) is placed in


2. Push the switch on the DBM upward two times.The display of the DBM will now show the temperature measuredby the first sensor.

3. Push the switch on the DBM upward one more time.The display of the DBM will now show the temperature measuredby the second sensor.

4. You can return to the default display (current time) by moving theDBM switch downward three times. Alternatively, you can waitfor about 30 seconds. The display will then automatically return tothe time display.

5. Check that the temperatures displayed on the DBM are not closeto the temperature setpoint specified in the FSC systemconfiguration (Install / Modules / Central parts / DBM).If the temperatures are close to the defined setpoints, check theoperation of the air-conditioning and fans, and make sure thefilters are not obstructed.


Checkingvia FSC Navigator

To check the temperature sensors of the DBM, take the followingsteps: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 inthe FSC cabinet.)

The screen as shown in Figure 7-1 on page 94 will appear. This screenis for information purposes only. You cannot edit anything in thisscreen. The information displayed is updated continuously.

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The 'Temperature 1' field displays the temperature measured by thefirst sensor, and the 'Temperature 2' field the temperature measured bythe second sensor. Check that the temperatures displayed on the DBMare not close to the temperature setpoint specified in the FSC systemconfiguration (Install / Modules / Central parts / DBM). If thetemperatures are close to the defined setpoints, check the operation ofthe air-conditioning and fans, and make sure the filters are notobstructed.


7.3.4 Checking air flow obstruction

Air flowobstruction

Most FSC cabinets have one or more fans in the roof and filters in thedoor. 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, falseair with more dust particles may enter the FSC cabinet. The dustparticles 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 cabinethave failed, the temperature inside the FSC cabinet will rise.If the temperature detected by the DBM sensors goes below the lowtemperature shutdown setpoint or exceeds the high temperatureshutdown setpoint, the affected Central Part of the FSC system willautomatically 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 fusehas the correct measurements and rating. If the fuse blowsinstantly, 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 threeoptions:− 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 thepower distribution drawings, which are part of the project-relateddocumentation.For details on the exact locations of the fuses and/or circuit breakersrefer to the general drawings, which are part of the project-relateddocumentation.

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 LEDremains on, the earth fault still exists and should be resolved (see thenext page).

Verify the correct operation of the ELD by checking the auxiliarycontact of the ELD. The auxiliary contact of the ELD is normallywired to a digital input module in the FSC cabinet or to terminals forexternal use. Under normal conditions (i.e. no earth fault detected), thedigital input should be high. If wired to terminals, the contact on theseterminals 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 ispresent. 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 powerdistribution drawings, which are part of the project-relateddocumentation.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-relateddocumentation.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-relateddocumentation.

How to solveearth faults

The procedure to trace an earth fault is identical for both types ofearth leakage detectors. The following equipment is required to tracean 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, thevoltmeter will display a steady value. If the clamp is placed on a cablewith an earth fault, the signal will pulse due to the frequencygenerated by the ELD. Please note that the frequency and signal valueof the ELD is very small compared to, for example, a 50 Vac/50 Hzsignal.

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 ELDto the "RESET" position. If the red LED remains on, the earthfault 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 theswing 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 thisstep until the earth fault is detected. The rack number in which theearth fault is present is then known.

7. Check each single SIC cable at the rear of the I/O rack until theearth fault has been located.

8. Once you know the affected module, you can identify thecorresponding FTA using the termination details.

9. Locate the FTA and check each individual signal pair connectedto the FTA until you have located the earth fault.

10. The cause of the earth fault is most likely located at the fielddevice.

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 statusof signals

To retrieve information on the loop status of the signals, take thefollowing 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 modulewith line-monitoring capabilities) whose loop status is not OK.

For technical details on the above modules refer to the FSC HardwareManual.

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 statusof signals

You should also check whether the signals that are forced in the FSCsystem still need to be forced. To retrieve information on the forcedsignals, 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 thatare currently forced (analog/digital inputs, analog/digital outputs, andmarkers) (see Figure 7-3 below).

Figure 7-3 Listing all forces in the system

The variables are represented by their rack, position, channel, type andtag number. If no variables are forced, a message will be displayed. Ifthe list does not fit on the screen, you can use the arrow keys on thekeyboard to scroll through the list.Check whether the signals listed still need to be forced. Make sure thatyou 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. Ifyou detect any paint damage, you should immediately touch up thedamaged spots. This is the only way to prevent corrosion of the FSCcabinets.

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 differentcolors are used.

7.3.10 Checking the availability of spare parts

Spare parts To avoid any problems with spare parts when they are urgentlyneeded, 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 localHoneywell representative.

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7.3.11 Checking the system diagnostics

Diagnostics The system diagnostics provide valuable information on the systemstatus. In order to guarantee problem-free operation of the FSCsystem, it is essential that you regularly check the system diagnostics.You can check the system diagnostics using the FSC Navigatorsoftware (running on an FSC user station connected to the FSCsystem). If you choose the "Extended Diagnostics" option in theOn-Line menu of FSC Navigator, all diagnostic messages from thecurrent application are retrieved from the system and displayed onscreen (see Figure 7-4 below). If there are no errors, this will bereported as well.

Figure 7-4 Checking the system diagnostics


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If there are any error messages, the following information is displayedon 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 ofthe FSC Software Manual ("On-Line Environment").For details on how to act on reported messages refer to Section 8 ofthis manual ("Troubleshooting and Fault-Finding").

7.3.12 Checking the backup of the application files

Application files It is important that you always have a backup of the application filesin your project directory. The project directory is a subdirectory ofthe FSC application directory (C:\FSC by default). The name of thedirectory is identical to the project name. Thus, if you have a projectcalled 'PROJ', the corresponding project files will be located in asubdirectory called 'PROJ' (usually C:\FSC\PROJ\).

Make sure that the backup comprises the most recent version of theapplication. If that is not the case, make a backup of all files in theproject directory for backup. This ensures that the diagnosticinformation from the FSC system (obtained using the "ExtendedDiagnostic" option) is also included.These files can then be viewed off-line at a later stage using the FSCNavigator software.

It is recommended that you use removable storage media for yourbackup (e.g. floppy disk, CD-R, or ZIP disk).

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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 everypower-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 insubsection 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. Ifthey 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) arecovered by a protective plate or cover. If these voltages areconnected, take extra precautions when the protective plates/coversare removed.After checking the voltages, make sure that you put the protectiveplates/covers back into place.

Externally suppliedvoltages

To check all DC voltages that are supplied externally, take thefollowing steps:1. Use a multimeter to measure the DC voltages on the incoming

fuse terminals and/or main circuit breakers located in the FSCcabinet.

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 adjustedto 25 Vdc (identical to the approved Delta power supply unitssupplied by HSMS). This is to ensure that the voltage at themodules will always be in accordance with requirements, takinginto account the voltage drop in the FSC cabinet.

For details on the exact locations of the fuse terminals and/or maincircuit breakers refer to the general drawings, which are part of theproject-related documentation.For details on the voltages that apply to specific FSC cabinets refer tothe power distribution drawings, which are part of the project-relateddocumentation.

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Voltages generatedby PSUs

To check all DC voltages generated by power supply units (PSUs) inthe 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 adjustedto 25 Vdc (identical to the approved Delta power supply unitssupplied by HSMS). This is to ensure that the voltage at themodules will always be in accordance with requirements, takinginto account the voltage drop in the FSC cabinet.

For details on the exact locations of the busbars and/or circuit breakerrack refer to the general drawings, which are part of the project-relateddocumentation.For details on the voltages that apply to specific FSC cabinets refer tothe power distribution drawings, which are part of the project-relateddocumentation.

7.4.3 Checking the power distribution fuses

Power distributionfuses

If separate power supply unit cabinets are supplied, it is possible thatfuses 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 generaldrawings, which are part of the project-related documentation.For details on the applicable fuse ratings refer to the powerdistribution drawings, which are part of the project-relateddocumentation.

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7.4.4 Checking the AC voltages

AC voltages All incoming AC voltages connected to the FSC cabinet via fuseterminals 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 notmeet the requirements laid down in the data sheets of the powersupply units (contained in the FSC Hardware Manual), the FSCsystem and the equipment may be damaged or they may notfunction properly.

For details on the exact locations of the fuse terminals and/or maincircuit 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 tothe power distribution drawings, which are part of the project-relateddocumentation.


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7.4.5 Checking the correct operation of the PSUs

Operationof PSUs

To ensure correct operation of the FSC system, all AC/DC powersupply units located in the FSC cabinet need to be operational andfunctioning 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 iswired to a digital input module placed in the FSC cabinet or toterminals for external use. (The contacts of the power supply unitsmay be wired in series or individually, depending on the customerrequirements.) Under normal conditions, all digital inputs that arewired from the power supply units should be high. If wired toterminals, the contact on these terminals should be closed. (Thisshould be checked on the external device.)

For details on the exact locations of the AC/DC power supply unitsand terminals refer to the general drawings, which are part of theproject-related documentation.For details on the wiring of the voltage-monitoring contact of theAC/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 becleaned using an anti-static soft brush. The inside of the FSC cabinetcan be cleaned using a vacuum cleaner.

Note:To check the dust concentration, the Central Part modules andI/O modules need to be removed from the Central Part and I/Oracks. To do this without any risk of personal injury and/orequipment damage, the FSC system needs to be powered down.For detailed information on how to perform a power-down referto Appendix B of this Service ManualFor detailed information on how to perform a power-up refer toAppendix 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 commonlymounted in the front and/or rear doors. Before replacing the dustfilter, 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 generaldrawings, 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 powerdistribution rails

If separate power supply unit cabinets are supplied, it is possible thatpower distribution rails are present in the FSC cabinet and the powersupply unit cabinet. The fasteners used on this power distributionrails 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 thepower distribution rail as a short circuit may cause a stop ofthe 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 tothe general drawings, which are part of the project-relateddocumentation.For details on the tightening torque of the fasteners refer to the datasheets of the manufacturer.


7.4.9 Checking all cable clamps

Cable clamps The cables entering the FSC cabinet are clamped to a cablesupport/clamp rail, which may be mounted in the FSC cabinet orbelow a false floor.If the cables are no longer clamped to the cable support/clamp rail, theweight of the cables might put tension on the connections between thecables and the connecting devices, which may result in a loss ofsignals 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 referto the general drawings, which are part of the project-relateddocumentation.For details on the tightening torque of the cable clamps refer to thedata sheets of the manufacturer.

7.4.10 Checking all shield connections

Shieldconnections

The shields of the field and system cables that carry signals fromcertain modules should be connected to the cable support/clamp rail(see Figure 7-5 on the next page). This is in accordance with CErequirements. You should check whether these cables are stillproperly connected.

The above requirement applies to signals from the following moduletypes:• 10102/x/x (analog input module)• 10214/x/x (loop-monitored digital output module)• 10216/x/x (loop-monitored digital output module)


Cable clamps

Cable clamp rails

Figure 7-5 Bonding of shielded cables

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7.4.11 Checking all earth/ground connections

Earth/groundconnections Three different earth/ground bars may be available in FSC cabinet:

• Safety earth/ground,• Instrument earth/ground (also called master reference ground, or


A correct earth/ground connection is required to ensure properoperation of the FSC system.

Safetyearth/ground

All mechanical parts of the FSC cabinet are connected to the safetyearth/ground bar, which is installed in the FSC cabinet to ensurecorrect operation.

An earth strap is connected from the safety earth/ground bar to thestructure of the FSC cabinet. Make sure that the safety earth/ground isstill properly connected.

The cable of the plant safety earth/ground can be connected to thesafety earth/ground bar or a safety earth/ground bolt in the FSCcabinet.

Instrumentearth/ground

The instrument earth/ground bar is used to connect the shields of fieldcables and the instrument earth/ground wire of the communicationmodules. Make sure that the instrument earth/ground is still properlyconnected.

The cable of the plant instrument earth/ground can be connected to theinstrument 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 properlyconnected.

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 framethat 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 systemconfiguration:• 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 withredundantCentral Parts

The procedure below discusses how to check and test the hardwareI/O for an FSC system with redundant Central Parts.After completion of this procedure, the redundancy for all hardwareI/O has been proved.

Notes:1. During this procedure one Central Part will be stopped.

Before proceeding with the procedure, use the "ExtendedDiagnostic" option of the FSC Navigator software to makesure that the other Central Part is fully operational.

2. The procedure below assumes that the FSC system is nolonger controlling the process. Contact the operators forverification.

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/Owill be checked and tested with Central Part 2 operational.

2. Simulate all digital and analog inputs of the FSC system. This canbe done on the terminals of the FTAs or terminals mounted in theFSC cabinet or the marshalling cabinet. The status of the digitaland analog inputs can be checked using the "FSC On-LineEnvironment" option of the FSC Navigator software.

3. Simulate all digital and analog outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of theFSC Navigator software. Measure all digital and analog outputs

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terminals of the FTAs or terminals mounted in the FSC cabinet orin the marshalling cabinet.

4. Start Central Part 1 as described in Appendix C of this ServiceManual.

5. Stop Central Part 2 of the FSC system as described in Appendix Bof this Service Manual. From this point onward, all hardware I/Owill be checked and tested with Central Part 1 operational.

6. Simulate all digital and analog inputs of the FSC system. This canbe done on the terminals of the FTAs or terminals mounted in theFSC cabinet or in the marshalling cabinet. The status of the digitaland analog inputs can be checked using the "FSC On-LineEnvironment" option of the FSC Navigator software.

7. Simulate all digital and analog outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of theFSC Navigator software. Measure all digital and analog outputsterminals of the FTAs or terminals mounted in the FSC cabinet orin the marshalling cabinet.


Systems with asingle Central Part

The procedure below discusses how to check and test the hardwareI/O for an FSC system with a single Central Part.

Note:The procedure below assumes that the FSC system is no longercontrolling 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 theFSC cabinet or the marshalling cabinet. The status of the digitaland analog inputs can be checked using the "FSC On-LineEnvironment" option of the FSC Navigator software.

2. Simulate all digital and analog outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of theFSC Navigator software. Measure all digital and analog outputsterminals of the FTAs or terminals mounted in the FSC cabinet orin the marshalling cabinet.

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7.4.13 Testing all communication links to external devices

Communicationlinks to externaldevices

All communication links to external devices can be checked andtested during the time frame that an FSC system does not control andmonitor the process (e.g. during a scheduled process shutdown).Either of two procedures should be used, depending on the systemconfiguration:• 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 withredundantCentral Parts

The procedure below discusses how to check and test the externalcommunication links for an FSC system with redundant CentralParts.After completion of this procedure, the redundancy for allcommunication links has been proved.

Notes:1. During this procedure one Central Part will be stopped.

Before proceeding with the procedure, use the "ExtendedDiagnostic" option of the FSC Navigator software to makesure that the other Central Part is fully operational.

2. The procedure below assumes that the FSC system is nolonger controlling the process. Contact the operators forverification.

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, allcommunication links will be checked and tested with CentralPart 2 operational.

2. Simulate all digital and binary inputs of the FSC system. Thismust be done via the external devices connected to the FSCsystem. The status of the digital and binary inputs can be checkedusing the "FSC On-Line Environment" option of the FSCNavigator software.

3. Simulate all digital and binary outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of the

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FSC Navigator software, and must be checked via the externaldevices connected to the FSC system.


5. Stop Central Part 2 of the FSC system as described in Appendix Bof this Service Manual. From this point onward, allcommunication links will be checked and tested with CentralPart 1 operational.

6. Simulate all digital and binary inputs of the FSC system. Thismust be done via the external devices connected to the FSCsystem. The status of the digital and binary inputs can be checkedusing the "FSC On-Line Environment" option of the FSCNavigator software.

7. Simulate all digital and binary outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of theFSC Navigator software, and must be checked via the externaldevices connected to the FSC system.


Systems with asingle Central Part

The procedure below discusses how to check and test thecommunication links for an FSC system with a single Central Part.

Note:The procedure below assumes that the FSC system is no longercontrolling 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 FSCsystem. The status of the digital and binary inputs can be checkedusing the "FSC On-Line Environment" option of the FSCNavigator software.

2. Simulate all digital and binary outputs of the FSC system. Thiscan be done using the "FSC On-Line Environment" option of theFSC Navigator software, and must be checked via the externaldevices connected to the FSC system.

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Section 8: Troubleshooting and Fault-Finding 121

Section 8 – Troubleshooting and Fault-Finding


Section overview This section describes the troubleshooting and fault-finding inconnection with the FSC system. It covers the following topics:


8.1 Section overview........................................................................................... 1218.2 Notification of alarms and errors................................................................... 1228.3 Retrieving diagnostic information from the FSC system .............................. 1238.3.1 Visible and/or audible alarms ....................................................................... 1238.3.2 FSC Navigator software................................................................................ 1238.3.3 Diagnostic and Battery Module (DBM) ......................................................... 1258.3.4 Sequence-of-Event (SOE) station ................................................................ 1258.4 Acting on the information retrieved............................................................... 127


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122 Section 8: Troubleshooting and Fault-Finding

8.2 Notification of alarms and errors

Notification ofalarms and errors

There are a number of ways in which the user can be informed of analarm/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 aboveoptions may be actually used. Each of these options is discussed inmore 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 beoverwritten.

2. The only correct way of retrieving extended diagnosticinformation from the FSC system is by using the "ExtendedDiagnostics" option of the FSC Navigator software. If youchoose this option, the information is also automaticallystored on the hard disk of the FSC user station for futurereference. For details refer to Section 12 of the FSCSoftware Manual.

3. Always retrieve extended diagnostics prior to activating theFSC reset key switch. If this key switch is activated, thebuffer in the FSC system is cleared and all alarm/errorinformation is lost.

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8.3 Retrieving diagnostic information from the FSC system

Retrievingdiagnosticinformation

As described in the previous subsection, the user can be notified ofalarms and errors in a number of different ways. The diagnosticinformation that accompanies these alarms and errors can also beretrieved in different ways. Each of these is discussed in thefollowing subsections.

8.3.1 Visible and/or audible alarms

Visible and/oraudible alarm

Functional Logic Diagrams (FLDs) can be designed which willactivate a digital output if an alarm/error is detected in the FSCsystem. This digital output will subsequently trigger a visible and/oraudible signal.After acknowledging this visible and/or audible alarm, the operatorwill have to investigate the cause of the alarm. This can be done indifferent ways as described below in the next few subsections.

8.3.2 FSC Navigator software

Using anFSC user station

The FSC Navigator software (running on an FSC user stationconnected to the FSC system) allows you to retrieve the most detailedinformation on the status of the FSC system. This information can beretrieved using the "Extended Diagnostics" option of FSC Navigator.If you choose this option, FSC Navigator retrieves all diagnosticmessages from the current application and displays them on screen(see Figure 8-1 on the next page). All diagnostic data that is retrievedfrom 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 ascendingchronological order, i.e. the most recent event is shown on the lastline.

All diagnostic information that is retrieved from the application isstored in the extended diagnostics database. If the FSC system has aredundant configuration, FSC Navigator retrieves and stores thediagnostic information from all Central Parts. The diagnosticinformation 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 canuse the up and down arrow keys (↑ and ↓ ) or <PgUp> and <PgDn> tobrowse through the list.

For further details on the information retrieved by the FSC Navigatorsoftware refer to Section 12 of the FSC Software Manual.

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8.3.3 Diagnostic and Battery Module (DBM)

Using the DBM The displays of the Diagnostic and Battery Module (DBM, HSMStype 10006/x/x) in the Central Part rack(s) continuously providestatus information of the FSC system. In default mode, the currenttime is shown. Diagnostic information, if available, can be retrievedby (repeatedly) pushing the switch on the DBM module downward.For details on how to interpret the diagnostic information displayedrefer 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 shoulduse the FSC Navigator software to interface with the FSCsystem (see subsection 8.3.2).

2. Before replacing modules or activating the reset key switchof the FSC system, always retrieve detailed diagnosticinformation by using the FSC Navigator.

8.3.4 Sequence-of-Event (SOE) station

Usingan SOE station

If a sequence-of-event recording (SER) device has been configured inthe FSC application, each individual I/O signal can be set to"SER-enabled". This means that if the SER-enabled tag numberchanges state, the information from that particular tag number is sentto an SOE station with the HSMS proprietary FSCSOE softwarerunning on it. This is a Windows-based application which retrievesevents from the FSC system and stores them in a database. The usercan view the events on-line (i.e. while being retrieved from theconnected 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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If no SOE station is connected to the FSC system, the SERinformation is stored in a buffer, which can hold at least 448 events. Ifthe 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 isgeneral information. If, for example, a communication erroris detected, no information is provided as to whichcommunication interface is affected. If you want moreextensive information, you should use the FSC Navigatorsoftware to interface with the FSC system (see subsection8.3.2).

2. Before replacing modules or activating the reset key switchof the FSC system, always retrieve detailed diagnosticinformation by using the FSC Navigator.

External devices It is also possible to communication with external devices, forexample:• RS-232 Modbus communication to an EPLC gateway, or• Using the FSC-SMM for communication with the UCN.

RS-232 Modbuscommunication

If RS-232 Modbus communication is used, additional FLDs need tobe designed which will ensure that the external device is informed ofthe alarm/error messages generated.

FSC-SMMcommunication

The FSC system can be integrated into the TPS system using the FSCSafety Manager Module (FSC-SMM). If that is the case, the FSCdiagnostics are also available at the TPS operator stations (US, UXS,GUS).

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8.4 Acting on the information retrieved

Actions Action needs to be taken based on the information retrieved from theFSC system. The following procedure should be followed:1. Examine the diagnostic information retrieved from the FSC

system. This information will provide details on why thealarm/error message was generated by the FSC system andwhether action has already been taken by the FSC system.For detailed information on the alarm/error messages retrievedfrom the FSC system refer to Section 12 of the FSC SoftwareManual.

2. Solve the cause of the alarm/error message. The extendeddiagnostics will help you identify the cause of the alarm/error anddefine 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.


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Section 9: Service and/or Modification to the FSC Cabinet 129

Section 9 – Service and/or Modification to the FSC Cabinet


Section overview This section provides information on the servicing and modificationsthat can be performed on the FSC cabinets. It covers the followingtopics:


9.1 Section overview........................................................................................... 1299.2 Service and modification overview ............................................................... 1309.2.1 Important considerations .............................................................................. 1309.2.2 On-line modification ...................................................................................... 1319.3 Hardware service and/or modification to the FSC cabinet ........................... 1329.3.1 Introduction ................................................................................................... 1329.3.2 Adding a communication module ................................................................. 1329.3.3 Adding an I/O rack ........................................................................................ 1339.3.4 Adding I/O modules ...................................................................................... 1339.3.5 Adding wiring to existing circuit breaker ....................................................... 1349.3.6 Changing converter modules........................................................................ 1359.3.7 Calibrating transmitters................................................................................. 1389.3.8 Key coding .................................................................................................... 1389.3.9 Updating documentation............................................................................... 1399.4 Software service and/or modification to the FSC cabinet............................. 1409.4.1 Introduction ................................................................................................... 1409.4.2 Verifying the application files ........................................................................ 1409.4.3 Backing up the application files .................................................................... 1419.4.4 Adding/changing FLDs ................................................................................. 1429.4.5 Renumbering FLDs....................................................................................... 1439.4.6 Adding/changing timers ................................................................................ 1439.4.7 Changing counters........................................................................................ 1439.4.8 Loopback of sheet references ...................................................................... 1449.4.9 EPROM/RAM size ........................................................................................ 1469.4.10 Square root of a negative value.................................................................... 1469.4.11 Divide by zero ............................................................................................... 1469.4.12 Range-checking errors ................................................................................. 147

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130 Section 9: Service and/or Modification to the FSC Cabinet

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. Theseactions should therefore be carried out with the utmost care,and by authorized and qualified persons only. In case ofproblems during the service or modification work, the FSCsystem can go to a safe state resulting in a processshutdown.

2. Before any service or modification work is done on the FSCsystem, make sure that all permits have been obtained fromthe plant operator.


It is recommended that a Honeywell SMS representative is present toperform an on-line modification. This is to ensure that the correctprocedures are being followed. Moreover, should any problems ariseduring the modification, they can be solved on the spot.

Restrictions andneed-to-know items

For restrictions and need-to-know items for hardware-relatedservice and/or modifications refer to subsections 9.3.For restrictions and need-to-know items for software-related serviceand/or modifications refer to subsection 9.4.

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9.2.2 On-line modification

On-linemodification

On-line modification (OLM) is a TÜV-approved FSC system optionwhich allows you to modify the application software, system softwareand the FSC hardware configuration of redundant systems, while thesystem remains operational. During on-line modification, the changesare upgraded in one Central Part at a time. Meanwhile, the otherCentral Part continues to monitor the process.An on-line modification can only be performed on an FSC systemwith redundant Central Parts and with the on-line modificationparameter of the application activated (i.e. set to "Yes" in the FSCconfiguration database).

Note:For more detailed information on on-line modifications to theFSC system refer to Appendix D of the FSC Software Manual("On-Line Modification").

Risks Considerable human interference may be required during on-lineservice and/or modification to the FSC system. This will greatlyincrease the risk of an error which may result in an alarm generatedor error detected by the FSC system and/or a stop of one or moreCentral Parts in the FSC system. This, in turn, may result in a totalplant trip.

It is therefore strongly recommended to only perform service and/ormodification work if it is really required and if the process in the plantallows it. Updating service or qualification descriptions of tagnumbers or adding text on FLD pages are generally not worth the riskof 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 FSCNavigator software to verify that both Central Parts are fullyoperational before starting the on-line modification.

2. During the time that one of the Central Parts of an FSCsystem with redundant Central Parts is stopped, the FSCsystem is not running with increased or high availability.

3. The FSC cabinet may have two Central Parts that do notcontain identical communication interfaces. It will then bepossible to perform an on-line modification, but informationto/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 modificationto the FSC cabinet. It covers the restrictions and need-to-knowinformation 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 acommunicationmodule

The communication modules are placed in the Central Part of theFSC system. A system bus is mounted at the rear of the Central Part.The following items need to be taken into consideration when addinga communication module:• Verify that the installed DC/DC converter (HSMS type 10300/1/1)

has sufficient spare capacity to supply power to the additionalcommunication 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 FSCHardware 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 FSCsystem has been powered down. This is because the vertical busflatcables, the flatcables to the horizontal buses and/or the HorizontalBus 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 addingI/O modules to an operational FSC system. It will help prevent thatan FSC system will stop due to an error found on a newly installedI/O module at the moment the new application is loaded into the FSCsystem.There is no difference between adding I/O modules in a non-redundant ("single") I/O section or a redundant I/O section.

Take the following steps when adding new I/O modules to anoperational 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/Omodules 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

Adding wiringto an existing circuitbreaker

If the new I/O modules are assigned to an existing group, you mayneed to add the external I/O wiring to an existing circuit breaker.Normally the wiring on the secondary side of the circuit breaker islooped from the circuit breaker, via all pins on the rear of the I/Obackplanes (HSMS type 1031x/x/x), and reconnected to the secondaryside of the circuit breaker.The recommended modification procedure depends on the status ofthe FSC system:• All Central Part(s) stopped,• Powered down, or• Fully operational.

Note:Any mistake during this modification may result in a stop of theCentral Part(s) of the FSC system. It is therefore recommendedthat any wiring modifications are carried out with the FSCsystem fully powered down (if possible).

All Central partsstopped

When all Central Parts of an FSC system are stopped, power downthe FSC system to avoid any damage to the electronic equipmentand/or injury to people during the modification.

FSC systempowered down

If the FSC system is powered down, the loop from the secondary sideof the circuit breaker can be disconnected from the rear of the I/Obackplane. You can then carry out all modification required toconnect power to the new I/O modules.

FSC systemfully operational

If the FSC system is fully operational and cannot be stopped, it isrecommended that you add a new circuit breaker for the new I/Omodules. In this way no modifications to existing wiring need to bemade.

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9.3.6 Changing converter modules

Changingconverter modules

Converter modules are placed at the rear of the backplane, and theyare used to set the ranges for the analog input and output module andthe sense for the digital output module.Converter modules (identified by 10xxx/A/x) are available for thefollowing 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 theFSC Hardware Manual.

Removal of converter modules from the backplane is detected by theFSC system. The next few pages discuss the system response for thevarious I/O module types.

Note:The converter modules for unallocated channels can be changedwithout any problems. The on-line features of FSC Navigatorallow you to check the channels before allocating a tag number.

10102/2/1 analoginput module

If a converter module of a 10102/2/1 analog input channel isremoved, the analog input signal is lost. This behavior is identical forFSC systems with redundant and/or non-redundant ("single") analoginput modules.If the converter module is removed, the Central Part(s) will report theloop status of the analog input signal as being faulty. The loop statusdiagnostic input SensAI will go to '0' (zero).The only way to prevent losing the analog input value and the SensAIdiagnostic input is forcing the analog input channel before removingthe converter module.

After the converter module has been exchanged, a system reset isrequired (by cycling the WD Reset key switch).

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10105/2/1 analoginput module

If the converter module of a 10105/2/1 analog input module isremoved, the 16 analog input signals allocated to this module are lost.This behavior is identical for FSC systems with redundant and/ornon-redundant ("single") analog input modules.If the converter module is removed, the Central Part(s) will report theloop status of the analog input signal as being faulty. The loop statusdiagnostic input SensAI will go to '0' (zero).The only way to prevent losing the analog input value and the SensAIdiagnostic input is forcing the analog input channel before removingthe converter module.

After the converter module has been exchanged, a system reset isrequired (by cycling the WD Reset key switch).

10106/2/1 digitalinput module

If the converter module is removed, the state of the digital inputsignal depends on the device connected. The only way to preventproblems is forcing the digital input signals.After the converter module has been exchanged, a system reset isrequired (by cycling the WD Reset key switch).

10205/2/1 analogoutput module

The 10205/2/1 analog output module is a fail-safe module, whichmeans that it has diagnostic capabilities. In case of a fault, the I/Omodule is able to detect the fault and respond to it. The action takendepends on the safety relation of the I/O signals allocated to thismodule.

I/O signalsnot safety related

If the converter module is removed, the output signal in the field islost and the output channel is reported faulty by the FSC system.After the converter module has been exchanged, a system reset isrequired (by cycling the WD Reset key switch).

I/O signalssafety related

If the converter module is removed, the output signal in the field islost and the output channel is reported faulty by the FSC system. Asthe output channel has been defined as safety-related, the total FSCsystem will stop.The only way to avoid this is to perform an on-line modificationduring which the safety relation of the analog output channelsallocated to the 10205/2/1 module is set to "No".The converter module can then be replaced without stopping the FSCsystem. After a system reset (using the WD Reset key switch) andverification that everything is in order, a second on-line modificationneeds to be performed to set the outputs allocated to the 10205/2/1module back to their original safety relation setting.

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Important!As an error on an analog output will result in a total stop of theFSC system, it is strongly recommended that the safety relationof analog output modules is always set to "No".

Note:For details on on-line modifications refer to Appendix D of theFSC Software Manual.

10216/2/x digitaloutput module

The 10216/2/x digital output module is a fail-safe module, whichmeans that it has diagnostic capabilities. In case of a fault, the I/Omodule is able to detect the fault and respond to it. The action takendepends on the safety relation of the I/O signals allocated to thismodule.

I/O signalsnot safety related

If the converter module is removed, the output signal in the field islost and the output channel is reported faulty by the FSC system.After the converter module has been exchanged, a system reset isrequired (by cycling the WD Reset key switch).

I/O signalssafety related

If the converter module is removed, the output signal in the field islost and the output channel is reported faulty by the FSC system. Asthe output channel has been defined as safety-related, the total FSCsystem will stop.The only way to avoid this is to perform an on-line modificationduring which the safety relation of the digital output channelsallocated to the 10216/2/x module is set to "No".The converter module can then be replaced without stopping the FSCsystem. After a system reset (using the WD Reset key switch) andverification that everything is in order, a second on-line modificationneeds to be performed to set the outputs allocated to the 10216/2/xmodule back to their original safety relation setting.

Note:For details on on-line modifications refer to Appendix D of theFSC Software Manual.

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9.3.7 Calibrating transmitters

Calibratingtransmitters

During the calibration stage of a transmitter, it is recommended thatyou force the analog input whose transmitter is being calibrated.When transmitters are calibrated, signals are superimposed on thenormal analog input signal. This will cause fluctuations in the analoginput signals, which will be detected by the FSC system.These fluctuation are handled as normal changes in the analog inputsignal, which might cause the safety application to respond. For FSCsystem with analog input modules placed in a redundant I/O rack, aninput compare error will be generated if the analog input value ofCentral Part 1 and Central Part 2 differ by more than 2% of the fullscale for the duration of the configured process safety time.

9.3.8 Key coding

Key coding The locations of the I/O modules in the I/O rack(s) are notpredetermined by FSC Navigator, but they are user-defined via theSystem Configuration option. To ensure proper interfacing with thefield devices (wiring, etc.) and to prevent damage to equipment, theI/O modules must be placed at the I/O rack positions as defined inFSC Navigator.To prevent insertion of an incorrect module type on a certain I/Oposition, the I/O rack connector and the module connector are key-coded with coding pins. If you add I/O modules, make sure that thecorrect 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 totalstop of the FSC system involved. It is therefore essential thatthe 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 referto the FSC Hardware Manual.

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9.3.9 Updating documentation

Updatedocumentation

If any hardware servicing and/or modifications are performed on theFSC cabinet, make sure that the master documentation set is updatedaccordingly.

Note:If you do not update the documentation, you may encounterproblems during maintenance, service and/or modification in thefuture.

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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 tothe FSC cabinet. It covers the restrictions and need-to-knowinformation 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

Verifyingapplication files

Before starting any modification to the FSC application, you need tomake sure the application in the FSC system is identical to theapplication that is stored on the FSC user station. This can be done ineither of the following two ways:1. Verification of the application, or2. Accessing 'live' FLDs.

Note:Both methods require a connection to your FSC system via anFSC Development System (FSC-DS) communication link.

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Applicationverification

To verify the application in the FSC system against the application onthe FSC user station, choose the 'Verify Application' option of FSCNavigator. For details refer to Section 11 ("Verifying anApplication") 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 Demoand Contractor versions of the FSC Navigator software.

Accessing'live' FLDs

An alternative verification method is by accessing 'live' FLDs. Toaccess '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 ofthe FSC application files is stored on the FSC user station.

Important!If the incorrect versions of FSC application files are used, anon-line modification to the FSC system cannot be completedwithout a total stop of the FSC system.

9.4.3 Backing up the application files

Backing upthe application files

After verification that the correct FSC application files are used, youshould always make a backup of the application files before carryingout any modifications. You should also make a backup after themodifications to the FSC system have been completed successfully.

Make a backup of all files in the applicable project directory. Theproject directory is always a subdirectory of the FSC applicationdirectory (C:\FSC by default). The name of the directory is identical tothe project name. Thus, if you have a project called 'PROJ', thecorresponding project files will be located in a subdirectory called

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'PROJ' (usually C:\FSC\PROJ\). Make sure that you remember thedirectory name, and that you copy all files in the project directory.

Important!Make sure that Windows 95/98 shows all files, and does nothide certain system files. Otherwise any FLDs with the number386 will not be backed up, which means your project can nolonger 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 toreboot your computer.

9.4.4 Adding/changing FLDs

Adding/changingFLDs

It is possible to delete, add and/or change FLDs during an on-linemodification. However, always make sure to check the impact of anydeletions, additions or changes to FLDs before carrying out the actualon-line modification.

After the FSC system is restarted, all FLDs (including the ones thatwere changed) are executed in accordance with the status of the inputsignals. This means, for example, that output signals may be affectedby the initial state of the related input signals, which may have aserious impact on the safety application. If, for example, a new digitalinput signal is added to an existing AND gate and this signal is not yetconnected 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 belost (i.e. set to '0') if the FSC system is (re)started. Depending on thesafety application, this might have an impact on the process.

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9.4.5 Renumbering FLDs

Renumber FLDs FLDs cannot be renumbered in the FLD design editor if the on-linemodification 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 modificationoption to "No", renumber the FLDs, and then change the on-linemodification option back to "Yes". The FLD numbering will thenindeed be updated. However, if you do this, the modifiedapplication cannot be loaded into the FSC system on-line (i.e.through an on-line modification). Instead, this should be doneoff-line. Any subsequent modifications can be performed on-lineagain (providing the on-line modification option is not set to "No"again.)

9.4.6 Adding/changing timers

Changing a timer Changing a timer value may cause the timer output to pulse for theduration of one cycle time. If you change a time value, make sure thatthe pulse of the timer output does not have an impact on the processcontrolled by the FSC system.

Adding a timer The input of variable timers may not go below 0 or exceed 2047.When adding timers during an on-line modification, always make surethat the input to the timer will never exceed the above values.If the timer input value does exceed the above values, the FSC systemwill automatically stop.

9.4.7 Changing counters

Changing counters The maximum counter value is defined in the FLDs (between 0 and8191). During normal operation of the FSC system, the counter inputvalue can be changed by activating the set input.When changing the maximum value of the counter, always make surethat the input value of the counter is not higher than the maximumvalue. Otherwise the FSC system will stop automatically.

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9.4.8 Loopback of sheet references

Loopback ofsheet references

A loopback is an off-sheet reference to a destination FLD with alower number than the source FLD. Even though the FSC Navigatorsoftware allows this, you should be cautious about using them.Loopbacks have certain consequences for value processing, whichmay be wanted behavior, but might also be design errors.

Note:FSC Navigator R510 and higher offer the Safety Checkeroption, which reports all loopback off-sheet references.

FLD100

FLD110

(A) Off-sheet reference to FLDwith higher number

Output Input

FLD100

FLD110

(B) Off-sheet reference to FLDwith lower number

Input Output

Figure 9-1 Off-sheet references and loopbacks

Off-sheet reference toFLD with higher number

Situation (A) in Figure 9-1 above shows a "normal" off-sheetreference. 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 FLDwith the lowest number.

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This means that any operation on the reference target (the input onFLD 110 in Figure 9-1) is done using the latest value of the referencesource (the output on FLD 100). No time is "wasted".

Off-sheet reference toFLD with lower number

Situation (B) in Figure 9-1 above shows an off-sheet reference thatrefers to an FLD with a lower number. Since the FSC system scansall hardware inputs only once per application cycle, this means thatfor one application cycle an operation on the reference target (theinput on FLD 100 in Figure 9-1) is done using an "old" value of thereference source (the output on FLD 110). After all, the input valueof the operation is not determined until later. It takes one applicationcycle for the reference target to be updated. If there are nestedloopbacks (i.e. a loopback in a loopback), the time delay will increaseby one application cycle for every nested loopback.

This time delay will usually not be wanted behavior, but design errorswhich may violate the intended functionality of the application.Loopbacks should therefore always be looked at very critically. Ifloopbacks cannot be avoided, it should be investigated which signalscan be looped back without violating the intended functionality of theapplication. For example, a loopback for MOS/OOS/bypass signals isno cause for alarm.

On-linemodification

It is possible to add loopbacks in an existing FSC system during anon-line modification. Please note that the power-up status for a newoff-sheet reference is set to "Off" by default. This means that if theloopback is added, the off-sheet reference and on-sheet reference willbe low for at least one cycle.Depending on the FLDs, this might result in a shutdown of one ormore units, or even a total plant shutdown. Adding loopbacks duringan on-line modification of an existing operational FSC system shouldtherefore 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 whichcontain 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 completedsuccessfully, check the translation log file. This log file will show thesize of the required EPROMs or RAM chips. Next, check the size ofthe EPROMs or RAM chips contained in the FSC system. If the sizesdo not match, new EPROMs or RAM chips are required, and jumpersetting on the Central Part modules will need to be changed.

For detailed information on the jumper setting of the Central Partmodules refer to the FSC Hardware Manual.

9.4.10 Square root of a negative value

Square root of anegative 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 cannever be a negative number.If the square-root function is performed on a negative number, theFSC system will stop automatically.

9.4.11 Divide by zero

Divide by 0 A divide-by-zero operation cannot be executed. When adding adivision function during an on-line modification, always make surethat the denominator can never be zero.If the denominator becomes zero, the FSC system will stopautomatically.

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9.4.12 Range-checking errors

Range-checkingerrors

The values used in the FSC system may not exceed their minimumand maximum values. If these minimum or maximum values areexceeded after a mathematical operation (subtraction, addition,multiplication, division or conversion), the FSC system will stopautomatically. To avoid this situation, additional logic may need to bedesigned.

Only downward conversions are allowed (see Table 9-1).

Table 9-1 Conversion table

Source Target ('To')

('From') B W L F

B – No No No

W Yes – No No

L Yes Yes – No

F Yes Yes Yes –

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 thevarious register types.

Table 9-2 FSC register types

Register type Integer/Real Minimum value Maximum value

Byte (8-bit) Integer –128 +127

Word (16-bit) Integer –32,768 +32,767

Long (32-bit) Integer –2,147,483,648 +2,147,483,647

Float (32-bit) Real –10e38 +10e38

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Section 10: Training Courses 149

Section 10 – Training Courses


Section overview This section provides general information on the courses availablewith respect to the FSC system. It covers the following topics:


10.1 Section overview........................................................................................... 14910.2 Training overview.......................................................................................... 15010.3 Fail Safe Controller Managers Overview course (4501) .............................. 15110.4 Introduction to IEC 61508 course (4504)...................................................... 15210.5 Fail Safe Controller Implementation course (4508)...................................... 15310.6 Fail Safe Controller Maintenance course (4505) .......................................... 15410.7 Fail Safe Controller On-Line Modification course (4502) ............................. 15510.8 Fail Safe Controller Advanced course (4512)............................................... 15610.9 Fail Safe Controller Total Package course ................................................... 15710.10 Customized training courses ........................................................................ 157

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150 Section 10: Training Courses

10.2 Training overview

Overview Various training programs are available which enable users tobecome familiar with the FSC system. The training courses can begiven at Honeywell locations, but they can also be organized on site,if required. The available training courses are listed below. Inaddition to a number of standard programs, there is also the option ofhaving training courses tailored to the customer's specific needs. Thisallows extra options to be added to the training, or it can be used tofocus on specific segments.

Whom to contact fortraining courses

For further details please contact your local Honeywell affiliate orHoneywell SMS Regional Delivery Center (RDC).

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 fewsubsections.

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10.3 Fail Safe Controller Managers Overview course (4501)

Overview This one-day course provides an overview of all basic features andfunctions of the FSC system. The course is intended for bothtechnical and non-technical managers in areas including operations,engineering, production, maintenance, purchasing, finance, andhuman resources. Students will learn what the FSC system is, what itcan do, what information it can provide, and what is involved inimplementing, operating, and maintaining it.

Prerequisites None.

Contents 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.

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10.4 Introduction to IEC 61508 course (4504)

Overview This one-day safety seminar provides an introduction to the newinternational safety standard IEC 61508, and helps you answer anumber of important safety questions (see below).

Prerequisites The following prerequisites are required:• Knowledge of process control.

Contents Many companies are currently working to implement the emerginginternational safety standard IEC 61508. The HSMS SafetyConsultancy group helps engineering contractors, system integratorsand end-users in the process industry adopt this standard andimplement its requirements in a structured manner. This one-daysafety seminar provides an introduction to the new internationalsafety standard IEC 61508, and helps you answer the followingimportant safety questions:1. What are the potential hazardous events and their associated risks,

and what risk reduction is required to achieve an acceptably safeprocess installation?

2. How can it be established and confirmed that the chosensafeguarding measures/equipment realize the required riskreduction (e.g. realize a specific SIL level)?

3. What activities need to be carried out to guarantee that this SILlevel is maintained during the entire lifetime of the safeguardedprocess installation?

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10.5 Fail Safe Controller Implementation course (4508)

Overview This four-day course provides the training for engineering personnelin the implementation of FSC projects. It covers the technical aspectsof the system, including safety and availability considerations.Programming of the system is included, as well as the communicationwith the Safety Manager Module (TPS100).

Prerequisites 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 PLCimplementation, configuration, and installation and maintenanceexperience.

• If the FSC is used in a TPS environment, knowledge of the LCNand UCN status and detail displays is required.

• Working knowledge of PC Windows interface (logging on, desktopoperation, navigation, starting programs, file operations).

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)

Overview This four-day course provides the training for maintenance personnelto enable them to support the FSC system with first-call maintenance.

Prerequisites 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 PLCimplementation, configuration, and installation and maintenanceexperience.

• If the FSC is used in a TPS environment, knowledge of the LCNand UCN status and detail displays is required.

• Working knowledge of PC Windows interface (logging on, desktopoperation, navigation, starting programs, file operations).

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) dataexchanges, and

• TPS100 (SMM) diagnostics.

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10.7 Fail Safe Controller On-Line Modification course (4502)

Overview This two-day On-Line Modification (OLM) course is required forthose how want to make changes to a running system ('on-line').Training is essential here, because on-line modification can have amajor impact on the process. If not done properly, OLM may lead toa total plant shutdown. All the exercises will be done using runningFSC systems. The OLM course can only be given at the HSMSCenter of Excellence in 's-Hertogenbosch, the Netherlands (NL33).

Prerequisites Participants to the OLM course must already have completed the FSCImplementation course (4508).

Contents 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.

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10.8 Fail Safe Controller Advanced course (4512)

Overview This five-day course covers the FSC system basics programming, theoperation, troubleshooting techniques, diagnostics and on-linechanges. Students perform systematic troubleshooting.Approximately 50% of course time is devoted to hands-on laboratoryexercises. The latest system hardware will be used in conjunctionwith the latest software features, such as flash memory operation("full download") and the PlantScape integration.

Prerequisites The Implementation course (4508) and experience with FSC systemsin general.

Contents 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.

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10.9 Fail Safe Controller Total Package course

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

10.10 Customized training courses

Overview Customized training courses are also available which are specificallygeared to the customer's specific needs. These courses will always beset up in cooperation with the customer, for example to focus on anydiscipline required for a particular site.

Training courses onspecific topics

Upon customer demand, special training courses are available thatfocus on particular FSC aspects (e.g. communication, sequence ofevents, alarming, FSC-FSC communication, etc.). These courses canalways be added to the courses mentioned above.For further details please contact your local Honeywell affiliate orHoneywell SMS Regional Delivery Center (RDC).

Courses forHoneywellemployees

Courses are available for the Honeywell integration centers that aregeared to service and training personnel. These training courses canonly 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 orHoneywell SMS Regional Delivery Center (RDC).

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Section 11: Decommissioning 159

Section 11 – Decommissioning


Section overview This section discusses the decommissioning of FSC systems. Itcovers the following topics:


11.1 Section overview........................................................................................... 15911.2 Decommissioning overview .......................................................................... 16011.3 Decommissioning procedure ........................................................................ 16111.3.1 Checking system operation .......................................................................... 16111.3.2 Powering down the FSC cabinet .................................................................. 16111.3.3 Disconnecting all cables ............................................................................... 16211.3.4 Removing all recyclable items ...................................................................... 16511.3.5 Removing all batteries .................................................................................. 16611.3.6 Removing the FSC cabinet........................................................................... 166

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160 Section 11: Decommissioning

11.2 Decommissioning overview

Whydecommissioning?

Proper decommissioning of an FSC cabinet is required to ensure thateverything is disposed of in the most environmentally friendlymanner possible. This can be achieved by removing environmentallyhazardous 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 morematerials can be recycled than described in this document.

Rules andguidelines

This section discusses the decommissioning activities of an FSCcabinet which is installed on site. They are described in accordancewith the rules and guidelines that apply in The Netherlands at thetime this document was issued. Before decommissioning of an FSCcabinet, make sure that you check the rules and guidelines that applyin the country where the FSC cabinet is located. It is possible that therules and guidelines have changed since the FSC cabinet wasinstalled.

Note:Disposal of environmentally hazardous items should be carriedout in accordance with local regulations.

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11.3 Decommissioning procedure

Decommissioningprocedure

The decommissioning procedure for FSC cabinets consists of thefollowing 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 followingsubsections.

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 controllingthe process may lead to dangerous situations. Contact the operators forverification.

11.3.2 Powering down the FSC cabinet

Powering downthe FSC cabinet

Power down the FSC cabinet as described in Appendix B of thisService Manual.

For details on the exact locations of the secondary circuit breakers,secondary disconnectors, primary switches and/or fuse terminalsmentioned in Appendix B refer to the general drawings, which are partof 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 fourdifferent 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 ofthem is discussed in more detail below.

Power/feedercables

Disconnect all incoming AC/DC power/feeder cables from the powerdistribution panel.

Note:If the AC/DC power/feeder cables are not disconnectedimmediately after powerdown of the FSC cabinet, use amultimeter to verify that the AC/DC power has beendisconnected on all incoming fuse terminals and/or main circuitbreakers located in the FSC cabinet.

The power/feeder cables for AC voltages will be connected to fuseterminals and/or a main circuit breaker located in the FSC cabinet.The power/feeder cables for DC voltages will be connected to fuseterminals located in the FSC cabinet.

Insulate the bare wires of the disconnected incoming AC/DCpower/feeder cables. This is to prevent dangerous situations whichmight lead to serious injury of people (e.g. when a circuit breaker inpower distribution board is accidentally activated).

For details on the exact locations of the fuse terminals and/or maincircuit breakers refer to the general drawings, which are part of theproject-related documentation.

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Field cables After disconnecting the power/feeder cables, you may disconnect thefield cables. The field cables are used to interconnect the FSC cabinetwith 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 passivedevices which simply pass incoming or outgoing signals between thefield and the I/O module. It is possible that the FTAs and/or terminalsare 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 onFTAs), the power can be supplied from external sources.If AC/DC voltages are still connected to the FSC cabinet, checkwhether these can be isolated from the external source.

Communicationcables

After disconnecting the field cables, you may disconnect thecommunication cables. The communication modules of the FSCsystem are placed in the Central Part(s). The communication cablescan be divided into three groups:• Fiber optic cables,• Tap trunk cables, and• Other communication cables.

For details on which communication cables should be disconnectedrefer to the communication drawings, which are part of the project-related documentation.For details on the exact locations of communication modules andconverters refer to the general drawings, which are part of the project-related 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 theCentral Part(s), fiber optic converter modules and/or splice panel inthe FSC cabinet.

Tap trunk cables Taps are mounted in the FSC cabinet for FSC—SMMcommunication with the Honeywell TotalPlant Solution (TPS)system.

Note:Make sure that the trunk cables can be disconnected without anyproblems. (Please note that the trunk cables are routed in amultidrop 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 multidroplink intact.

Other communicationcables

All other communication cables are connected to communicationmodules located in the FSC cabinet.

Note:Make sure that the communication cables can be disconnectedwithout any problems. (Please note that the FSC cabinet beingdecommissioned may be part of a multidrop communicationlink.)

Disconnect all communication cables that are connected to thecommunication modules in the FSC cabinet.

Peripheralequipment

After disconnecting the communication cables, you may disconnectall cables between the FSC cabinet and external communicationdevices. Check whether all peripheral equipment connected to theFSC 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 theyare not used by other devices.

Note:The FSC user station and/or SOE station should be disposed ofin accordance with local regulations. For decommissioninginformation for external devices connected to FSC cabinets referto the manufacturer's information.

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Earth/groundingcables

After disconnecting the cables between the FSC cabinet and externalcommunication devices, you may disconnect the earth/groundingcables. Three different earth bars may be present in FSC cabinet:• Safety earth/ground,• Instrument earth/ground (also called master reference ground, or


Safety earth/ground All mechanical parts of the FSC cabinet are connected to the safetyearth/ground bar, which is installed in the FSC cabinet to ensurecorrect operation.The cable of the plant safety earth/ground can be disconnected fromthe safety earth/ground bar or a safety earth/ground bolt in the FSCcabinet.

Instrument earth/ground The instrument earth/ground bar is used for connections of the shieldfrom field cables and the instrument earth/ground wire from thecommunication boards.

The cable of the plant instrument earth/ground can be disconnectedfrom 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 theEx(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 theCentral Part modules, I/O modules, FTAs and SIC cables, which canbe used as spare parts for other FSC cabinets.Visually inspect the items removed for any damage. Items that aredamaged in any way should not be used as spare parts. Test theremoved items using an FSC simulation and training unit (seeAppendix 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 ofpreventive maintenance. If removed items are to be used asspare parts, make sure they are entered into the preventive-maintenance 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 FSCcabinet.

Notes:1. You should never place DBMs and SBDs flat on a

conductive surface. The batteries placed on the DBM orSBD may then cause a short circuit which will damage themodule beyond repair.

2. Always place DBMs and SBDs straight up or in theiroriginal packaging.

3. Environmentally hazardous items, such as batteries, shouldbe disposed of in accordance with local regulations.

11.3.6 Removing the FSC cabinet

Removing theFSC cabinet

FSC cabinets are bolted down to the floor. After all the activitiesdescribed in the previous subsections have been completed, thesebolts may be removed. Make sure that the swing frame and doors areclosed to prevent the FSC cabinet from tipping over. Otherwisehazardous situations may arise which may lead to serious injury topeople.

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Appendix A of this Service Manual shows the locations of thebolt-down holes. For moving and hoisting instructions refer toSection 2 of this Service Manual.

Note:Environmentally hazardous items should be disposed of inaccordance with local regulations.

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Appendix A: Plinth Layouts 169

Appendix A – Plinth Layouts

A.1 Section overview

Section overview This appendix provides detailed information on the measurementsand locations of the bolt-down holes that are used to secure FSCcabinets to the floor. FSC cabinets can be delivered with or withoutplinths.


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

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170 Appendix A: Plinth Layouts

A.2 Introduction

Measurements Two standard Rittal cabinets types are used for FSC cabinets:• PS 4806:

Measurements: 80 x 60 x 200 cm (width x depth x height)(31½ x 23½ x 78¾ in).

• PS 4808:Measurements: 80 x 80 x 200 cm (width x depth x height)(31½ x 31½ x 78¾ in).

The standard plinth mounted below an FSC cabinet is 100 mm high(4 inches).

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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A.3 No plinth for one PS 4806 cabinet

One PS 4806,no plinth

Figure A-1 below shows the dimensions and locations of thebolt-down holes that are used for securing a Rittal PS 4806 cabinetwithout a plinth to the floor.All measurements are in millimeters (1 inch = 25.4 mm).

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

One PS 4806,plinth

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

Figure A-2 Plinth for one Rittal PS 4806 cabinet


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A.5 Plinth for two PS 4806 cabinets

Two PS 4806,plinth

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

Figure A-3 Plinth for two Rittal PS 4806 cabinets

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A.6 Plinth for three PS 4806 cabinets

Three PS 4806,plinth

Figure A-4 below shows the dimensions and locations of thebolt-down holes that are used for securing three Rittal PS 4806cabinets with a plinth to the floor.All measurements are in millimeters (1 inch = 25.4 mm).

Figure A-4 Plinth for three Rittal PS 4806 cabinets

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A.7 No plinth for one PS 4808 cabinet

One PS 4808,no plinth

Figure A-5 below shows the dimensions and locations of thebolt-down holes that are used for securing a Rittal PS 4808 cabinetswithout a plinth to the floor.All measurements are in millimeters (1 inch = 25.4 mm).

Figure A-5 No plinth for one Rittal PS 4808 cabinet


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A.8 Plinth for one PS 4808 cabinet

One PS 4808,plinth

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

Figure A-6 Plinth for one Rittal PS 4808 cabinet


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A.9 Plinth for two PS 4808 cabinets

Two PS 4808,plinth

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

Figure A-7 Plinth for two Rittal PS 4808 cabinets

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A.10 Plinth for three PS 4808 cabinets

Three PS 4808,plinth

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

Figure A-8 Plinth for three Rittal PS 4808 cabinets

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A.11 Plinth for four PS 4808 cabinets

Four PS 4808,plinth

Figure A-9 below shows the dimensions and locations of thebolt-down holes that are used for securing four Rittal PS 4808cabinets with a plinth to the floor.All measurements are in millimeters (1 inch = 25.4 mm).

Figure A-9 Plinth for four Rittal PS 4808 cabinets

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Appendix B: Stopping / Powering Down the FSC System 181

Appendix B – Stopping / Powering Down the FSC System

B.1 Section overview

Section This appendix provides detailed information on how to stop an FSCsystem and power down an FSC cabinet. It covers the followingtopics:


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

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182 Appendix B: Stopping / Powering Down the FSC System

B.2 Central Part configuration

Central Partconfiguration 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 orredundant), 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 followingsections.

Notes:1. Before starting a procedure to perform a stop of an FSC

system and/or powerdown of an FSC cabinet, make sure thatthe FSC system is no longer controlling the process.Stopping the Central Part(s) when the FSC system is stillcontrolling the process may lead to dangerous situations.Contact the operators for verification.

2. If any errors have been detected by the FSC system, it ispossible that one or both Central Parts have already stoppedautomatically.

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B.3 Stopping one CP of an FSC system with redundant CPs

Stopping one CP inredundant system

This section describes the correct procedure to stop one Central Partof 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 FSCNavigator software to verify that the other Central Part isfully operational before continuing with this procedure.

2. During the time that one of the Central Parts of an FSCsystem with redundant Central Parts is stopped, the FSCsystem is not running with increased or high availability.

Procedure The procedure below contains the description "Central Part". This canbe Central Part 1 or Central Part 2, depending on the Central Part tobe stopped. To stop one of the Central Parts, follow the procedurebelow.

Step 1 Check if the Central Part is already stopped.

Note:If any errors have been detected by the FSC system, it ispossible that one or both Central Parts have already stoppedautomatically.

If the Central Part is stopped, all of the following conditions should bemet:a) The 'On' LED on the Vertical Bus Driver (VBD, HSMS type

10001/x/x) should be off. It is possible that the Central Partcontains more than one VBD. In that case the 'On' LED of allVBDs 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, HSMStype 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 shouldbe 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 type10005/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 type10005/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 inStep 1 above should be met.

Step 3 Turn the key switch of the Central Processing Unit (CPU, HSMStype 10002/x/x or 10012/x/x) in the Central Part to the horizontalposition ("STOP").

Step 4 Identify which circuit breaker in the circuit breaker rack supplies the24 Vdc power to the Central Part that is being stopped, and switch itoff.

Notes:1. If is essential that the correct circuit breaker is deactivated.

If the incorrect circuit breaker is deactivated, this mightresult in a stop of the redundant Central Part. Stopping bothCentral Parts when the FSC system is still controlling theprocess may lead to dangerous situations.

2. For details on the exact location of the 24 Vdc circuitbreaker refer to the general drawings, power distributiondrawings and rack layout, which are all part of the project-related documentation.

At this point, one Central Part of the FSC system with redundantCentral Parts has been successfully stopped.

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B.4 Stopping both CPs of an FSC system with redundant CPs

Stopping both CPsin redundantsystem

This section describes the correct procedure to stop both Central Partsof an FSC system with redundant Central Parts.

Note:After completion of this procedure, both Central Parts will bestopped. Before starting the procedure, make sure that the FSCsystem is no longer controlling the process. Stopping the CentralPart(s) when the FSC system is still controlling the process maylead to dangerous situations. Contact the operators forverification.

Procedure To stop the Central Parts, follow the procedure below.

Step 1 Check if Central Part 1 is already stopped.


If Central Part 1 is stopped, all of the following conditions should bemet: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 theCentral 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, HSMStype 10006/x/x) in Central Part 1 should either be blank or notflashing.

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Step 2 If not all conditions of Step 1 above are met, Central Part 1 should bestopped 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 type10005/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 type10005/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 1above should be met.










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Step 5 Turn the key switches of the Central Processing Units (CPU, HSMStype 10002/x/x or 10012/x/x) in Central Parts 1 and 2 to theirhorizontal position ("STOP").

Step 6 Identify which circuit breakers in the circuit breaker rack supply the24 Vdc power to Central Parts 1 and 2, and switch them off.

Note:For details on the exact location of the 24 Vdc circuit breakersrefer to the general drawings, power distribution drawings andrack layout, which are all part of the project-relateddocumentation.

At this point, both Central Parts of the FSC system with redundantCentral Parts have been successfully stopped.

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B.5 Powering down an FSC system with redundant CPs

Powering downredundant system

This section describes the correct procedure to power down an FSCsystem with redundant Central Parts.

Note:After completion of this procedure, both Central Parts will bestopped and the FSC system will be powered down. Beforestarting the procedure, make sure that the FSC system is nolonger controlling the process. Stopping the Central Part(s)when the FSC system is still controlling the process may lead todangerous situations. Contact the operators for verification.

Procedure To power down an FSC system with redundant Central Parts, followthe procedure below.








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in Central Part 1 from the watchdog horizontal bus (HSMS type10005/O/1), which is located above the Central Part.Wait for two seconds and reconnect the flatcable.












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Step 5 Turn the key switches of the Central Processing Units (CPU, HSMStype 10002/x/x or 10012/x/x) in Central Parts 1 and 2 to theirhorizontal position ("STOP").

Step 6 Switch off all circuit breakers in the circuit breaker rack.

Step 7 Switch off all primary switches of the power supply units (PSUs)mounted in the FSC cabinet.

Step 8 Switch off all main circuit breakers mounted in the FSC cabinet.

Step 9 Switch off all secondary disconnectors of the PSUs mounted in theFSC cabinet.

Step 10 Remove all fuses from the incoming fuse terminals which the AC/DCpower/feeder cables are connected to.

Step 11 Switch off all circuit breakers in the power distribution panel whichprovides AC/DC power to the FSC cabinet.

Step 12 Use a multimeter to check that the power has been disconnected onall incoming power/feeder terminals/main circuit breakers.

At this point both Central Parts have stopped and the FSC cabinet hasbeen successfully powered down.

Note:For details on the exact location of the 24 Vdc circuit breakers,secondary disconnectors, primary switches and fuse terminalsrefer to the general drawings, power distribution drawings andrack layout, which are all part of the project-relateddocumentation.

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At this point, both Central Parts of the FSC system with redundantCentral Parts are stopped and the FSC cabinet has been successfullypowered down.

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B.6 Stopping the CP of an FSC system with a single CP

Stopping CPin single system

This section describes the correct procedure to stop the Central Partof an FSC system with a single Central Part.

Note:After completion of this procedure, the Central Part will bestopped. Before starting the procedure, make sure that the FSCsystem is no longer controlling the process. Stopping the CentralPart(s) when the FSC system is still controlling the process maylead to dangerous situations. Contact the operators forverification.

Procedure To stop the Central Part, follow the procedure below.




10001/x/x) should be off. It is possible that the Central Partcontains more than one VBD. In that case the 'On' LED of allVBDs 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, HSMStype 10006/x/x) should either be blank or not flashing.

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Step 4 Identify which circuit breaker in the circuit breaker rack supplies the24 Vdc power to the Central Part, and switch it off.

Note:For details on the exact location of the 24 Vdc circuit breakerrefer to the general drawings, power distribution drawings andrack layout, which are all part of the project-relateddocumentation.

At this point, the Central Part of the FSC system with a single CentralPart has been successfully stopped.

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B.7 Powering down an FSC system with a single CP

Powering downsingle system

This section describes the correct procedure to power down an FSCsystem with a single Central Part.

Note:After completion of this procedure, the Central Part will bestopped and the FSC system will be powered down. Beforestarting the procedure, make sure that the FSC system is nolonger controlling the process. Stopping the Central Part(s)when the FSC system is still controlling the process may lead todangerous situations. Contact the operators for verification.

Procedure To power down an FSC system with a single Central Part, follow theprocedure below.


Note:If any errors have been detected by the FSC system, it ispossible that the Central Part has already stopped automatically.


10001/x/x) in the Central Part should be off. It is possible that theCentral 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.


d) The displays of the Diagnostic and Battery Module (DBM, HSMStype 10006/x/x) in the Central Part should either be blank or notflashing.

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Step 4 Switch off all circuit breakers in the circuit breaker rack.

Step 5 Switch off all primary switches of the power supply units (PSUs)mounted in the FSC cabinet.

Step 6 Switch off all main circuit breakers mounted in the FSC cabinet.

Step 7 Switch off all secondary disconnectors of the PSUs mounted in theFSC cabinet.

Step 8 Remove all fuses from the incoming fuse terminals which the AC/DCpower/feeder cables are connected to.

Step 9 Switch off all circuit breakers in the power distribution panel whichprovides AC/DC power to the FSC cabinet.

Step 10 Use a multimeter to check that the power has been disconnected onall incoming power/feeder terminals/main circuit breakers.

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Note:For details on the exact location of the 24 Vdc circuit breakers,secondary disconnectors, primary switches and fuse terminalsrefer to the general drawings, which are part of the project-related documentation.

At this point, the Central Part of the FSC system with a single CentralParts is stopped and the FSC cabinet has been successfully powereddown.

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Appendix C: Starting Up / Powering Up the FSC System 197

Appendix C – Starting Up / Powering Up the FSC System

C.1 Section overview

Section This appendix provides detailed information on how to start an FSCsystem and power up an FSC cabinet. It covers the following topics:


C.1 Section overview........................................................................................... 197C.2 Central Part configuration ............................................................................. 198C.3 Starting one CP of an FSC system with redundant CPs .............................. 199C.4 Starting both CPs of an FSC system with redundant CPs ........................... 203C.5 Powering up an FSC system with redundant CPs ....................................... 209C.6 Starting the CP of an FSC system with a single CP..................................... 215C.7 Powering up an FSC system with a single CP ............................................. 218

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198 Appendix C: Starting Up / Powering Up the FSC System

C.2 Central Part configuration

Central Partconfiguration 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 orredundant), 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 followingsections.

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C.3 Starting one CP of an FSC system with redundant CPs

Starting one CP inredundant system

This section describes the correct procedure to start one Central Partof 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 Bof this Service Manual.

2. It is assumed that the other Central Part is already fullyoperational. If this is not the case, start both Central Parts inaccordance 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 thiscircuit breaker off).

• The key on the Central Processing Unit (CPU, HSMS type10002/x/x or 10012/x/x) in the Central Part is in the horizontalposition ("STOP").

• For watchdog horizontal bus 10005/O/1:The flatcables of the watchdog module (WD, HSMS type10005/x/x) in the Central Part are properly connected to thewatchdog horizontal bus (10005/O/1), which is located above theCentral Part.

• For watchdog horizontal bus 10005/O/2:The key of the watchdog horizontal bus (10005/O/2), which islocated above the Central Part, is in the horizontal position.

Procedure To start one Central Part of an FSC system with redundant CentralParts, follow the procedure below. It contains the description "CentralPart". This can be Central Part 1 or Central Part 2, depending on theCentral Part to be started.

Step 1 Activate the 24 Vdc circuit breaker for the Central Part.

Step 2 At this point the Diagnostic and Battery Module (DBM, HSMS type10006/x/x) can be in either of the following states:a) The displays of the DBM are blank, orb) The displays of the DBM show a time (not necessarily the actual

time).

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Step 3 Turn the key switch of the Central Processing Unit (CPU, HSMStype 10002/x/x or 10012/x/x) in the Central Part to the verticalposition ("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 applicationneeds 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 (notnecessarily the actual time), which is updated continuously. Youcan 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 areupdated.

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 havebeen removed from the Central Part, the information stored in theRAM chips is lost. The FSC application will then need to be loadedusing 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. (Pleasenote that this requires special Central Part modules that supportflash memory operation.) The application will then need to beloaded using the "Load Software" option of the FSC Navigatorsoftware. After all the software has been downloaded successfully,proceed with step 5 below.

Step 5 If the Central Part contains an FSC Safety Manager Module(FSC-SMM, HSMS type 100x8/2/U), the Personality Image (PI) forthe Central Part should be loaded from the TPS system. For details onhow to load the PI refer to Appendix D of the FSC Software Manual("On-Line Modification") or the TPS user manuals.

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Step 6 Cycle the WD reset key switch, which is located in one of the CentralParts.

Step 7 Check if the Central Part is running. If it is running, all of thefollowing 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 theCentral 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, HSMStype 10006/x/x) in the Central Part should show the current timeand should be flashing or steady.

Step 8 If not all conditions of step 7 above are met, the FSC system hasdetected an error which prevents the Central Part from starting up.In that case, use the "Extended Diagnostics" option of the FSCNavigator software to retrieve detailed error information from the FSCsystem. Any errors found need to be resolved before the WD reset keyswitch as mentioned in step 6 may be activated again.

Step 9 Repeat the above steps until the Central Part is operational.

Step 10 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 isfully operational.

b) If all conditions of step 7 above are met and the DBM displays ofCentral Part 1 and Central Part 2 are flashing, an alarm/error hasbeen detected in the FSC system. Use the "Extended Diagnostics"option of the FSC Navigator software to retrieve information fromthe FSC system. Resolve the reported alarm(s)/error(s) andactivate the WD reset key switch again. Repeat step 10 until theFSC system is fully operational without any errors.

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Note:For details on the exact location of the (main) circuit breakers,secondary disconnectors, primary switches and fuse terminalsrefer to the general drawings, which are part of the project-related documentation.

At this point, one Central Part of the FSC system with redundantCentral Parts has successfully started up.

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C.4 Starting both CPs of an FSC system with redundant CPs

Starting both CPs inredundant system

This section describes the correct procedure to start both Central Partsof an FSC system with redundant Central Parts.

Note:It is assumed that both Central Parts have been stopped inaccordance with the procedure as described in Appendix B ofthis 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 thesecircuit breakers off).

• The keys on the Central Processing Units (CPU, HSMS type10002/x/x or 10012/x/x) in the Central Parts is in the horizontalposition ("STOP").

• For watchdog horizontal bus 10005/O/1:The flatcables of the watchdog modules (WD, HSMS type10005/x/x) in the Central Parts are properly connected to thewatchdog horizontal buses (10005/O/1), which are located abovethe Central Parts.

• For watchdog horizontal bus 10005/O/2:The keys of the watchdog horizontal buses (10005/O/2), which arelocated 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 theprocedure below.

Step 1 Activate the 24 Vdc circuit breaker for Central Part 1.

Step 2 At this point the Diagnostic and Battery Module (DBM, HSMS type10006/x/x) in Central Part 1 can be in either of the following states:a) The displays of the DBM are blank, orb) The displays of the DBM show a time (not necessarily the actual

time).

Step 3 Turn the key switch of the Central Processing Unit (CPU, HSMStype 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,







c) The FSC system has been configured for FLASH mode. (Pleasenote that this requires special Central Part modules that supportflash memory operation.) The application will then need to be

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loaded using the "Load Software" option of the FSC Navigatorsoftware. 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) forthe Central Part should be loaded from the TPS system. For details onhow to load the PI refer to Appendix D of the FSC Software Manual("On-Line Modification") or the TPS user manuals.


Step 7 Check if Central Part 1 is running. If it is running, all of the followingrequirements 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 CentralPart 1 contains more than one VBD. In that case the 'On' LED of allVBDs should be on.

b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) inCentral Part 1 should be on.


d) The displays of the Diagnostic and Battery Module (DBM, HSMStype 10006/x/x) in Central Part 1 should show the current time andshould be flashing or steady.

Step 8 If not all conditions of step 7 above are met, the FSC system hasdetected an error which prevents Central Part 1 from starting up.In that case, use the "Extended Diagnostics" option of the FSCNavigator software to retrieve detailed error information from the FSCsystem. Any errors found need to be resolved before the WD reset keyswitch as mentioned in step 6 may be activated again.

Step 9 Repeat the above steps until Central Part 1 is operational.

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Step 10 Activate the 24 Vdc circuit breaker for Central Part 2.


time).









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10001/x/x) in Central Part 2 should be on. It is possible thatCentral Part 2 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 2 should be on.





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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 FSCsystem is fully operational.

b) If all conditions of steps 7 and 16 above are met and the DBMdisplays of Central Part 1 and Central Part 2 are flashing, analarm/error has been detected in the FSC system. Use the"Extended Diagnostics" option of the FSC Navigator software toretrieve information from the FSC system. Resolve the reportedalarm(s)/error(s) and activate the WD reset key switch again.Repeat step 19 until the FSC system is fully operational withoutany errors.


At this point, both Central Parts of the FSC system with redundantCentral Parts have successfully started up.

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C.5 Powering up an FSC system with redundant CPs

Powering up FSCsystem withredundant CPs

This section describes the correct procedure to power up an FSCsystem with redundant Central Parts.

Note:It is assumed that the FSC cabinet with redundant Central Partshas been powered down in accordance with the procedure asdescribed in Appendix B of this Service Manual.

Procedure To power up an FSC system with redundant Central Parts, follow theprocedure below.

Step 1 Turn the key switches of the Central Processing Units (CPU, HSMStype 10002/x/x or 10012/x/x) in both Central Parts to the horizontalposition ("STOP").

Step 2 For watchdog horizontal bus 10005/O/1:Make sure that the flatcables of the watchdog modules (WD, HSMStype 10005/x/x) in both Central Parts are properly connected to thewatchdog horizontal buses (10005/O/1), which are located above theCentral 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 thehorizontal position.

Step 3 Switch on all circuit breakers in the power distribution panel.

Step 4 Place all fuses in the incoming fuse terminals which the AC/DCpower/feeder cables are connected to.

Step 5 Switch on all secondary disconnectors of the power supply units(PSUs).

Step 6 Switch on all main circuit breakers.

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Step 7 Switch on all primary switches of the PSUs.

Step 8 Switch on all circuit breakers located in the circuit breaker rack.


time).









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time).









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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 FSCsystem is fully operational.

b) If all conditions of steps 14 and 22 above are met and the DBMdisplays of Central Part 1 and Central Part 2 are flashing, analarm/error has been detected in the FSC system. Use the"Extended Diagnostics" option of the FSC Navigator software toretrieve information from the FSC system. Resolve the reportedalarm(s)/error(s) and activate the WD reset key switch again.Repeat step 25 until the FSC system is fully operational withoutany errors.


At this point, the FSC system with redundant Central Parts hassuccessfully powered up.

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C.6 Starting the CP of an FSC system with a single CP

Starting CP insingle system

This section describes the correct procedure to start the Central Partof an FSC system with a single Central Part.

Note:It is assumed that the Central Part has been stopped inaccordance with the procedure as described in Appendix B ofthis 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.

Step 2 At this point the Diagnostic and Battery Module (DBM, HSMS type10006/x/x) can be in either of the following states:a) The displays of the DBM are blank, orb) The displays of the DBM show a time (not necessarily the actual

time).





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Step 6 Cycle the WD reset key switch, which is located in the Central Part.



b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) inthe Central Part should be on.



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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 inthe FSC system. Use the "Extended Diagnostics" option of the FSCNavigator software to retrieve information from the FSC system.Resolve the reported alarm(s)/error(s) and activate the WD resetkey switch again. Repeat step 10 until the FSC system is fullyoperational without any errors.


At this point, the Central Part of the FSC system with a single CentralPart has successfully started up.

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C.7 Powering up an FSC system with a single CP

Powering up FSCsystem withsingle CP

This section describes the correct procedure to power up an FSCsystem with a single Central Part.

Note:It is assumed that the FSC cabinet with a single Central Part hasbeen powered down in accordance with the procedure asdescribed in Appendix B of this Service Manual.

Procedure To power up an FSC system with a single Central Part, follow theprocedure below.


Step 2 For watchdog horizontal bus 10005/O/1:Make sure that the flatcable of the watchdog module (WD, HSMStype 10005/x/x) in the Central Part is properly connected to thewatchdog horizontal bus (10005/O/1), which is located above theCentral 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 Switch on all circuit breakers in the power distribution panel.

Step 4 Place all fuses in the incoming fuse terminals which the AC/DCpower/feeder cables are connected to.

Step 5 Switch on all secondary disconnectors of the power supply units(PSUs).

Step 6 Switch on all main circuit breakers.

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Step 7 Switch on all primary switches of the PSUs.

Step 8 Switch on all circuit breakers located in the circuit breaker rack.

Step 9 At this point the Diagnostic and Battery Module (DBM, HSMS type10006/x/x) in the Central Part can be in either of the following states:a) The displays of the DBM are blank, orb) The displays of the DBM show a time (not necessarily the actual

time).









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Step 13 Cycle the WD reset key switch, which is located in the Central Part.



b) The 'WD' LED on the watchdog module (HSMS type 10005/x/x) inthe Central Part should be on.





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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 inthe FSC system. Use the "Extended Diagnostics" option of the FSCNavigator software to retrieve information from the FSC system.Resolve the reported alarm(s)/error(s) and activate the WD resetkey switch again. Repeat step 18 until the FSC system is fullyoperational without any errors.


At this point, the FSC system with a single Central Part hassuccessfully powered up.

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Appendix D: Alarm/Error Messages and Solutions 223

Appendix D – Alarm/Error Messages and Solutions

D.1 Section overview

Section This appendix provides detailed information on the alarm/errormessages generated by the FSC system. In addition to the alarm/errormessages, information on the reasons for the alarm/error is providedas well as possible solution to resolve them.


D.1 Section overview........................................................................................... 223D.2 General messages........................................................................................ 224D.3 Analog input module 10102/x/x .................................................................... 225D.4 Analog input module 10105/2/1.................................................................... 226D.5 Analog output module 10205/2/1.................................................................. 227D.6 Communication errors with the FSC user station......................................... 228D.7 Output short circuit........................................................................................ 229D.8 Download not successful .............................................................................. 230D.9 Process trip during an on-line modification................................................... 231D.10 Calculation errors.......................................................................................... 232

For further details on the alarm/error messages generated by the FSCsystem refer to the FSC Software Manual.

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224 Appendix D: Alarm/Error Messages and Solutions

D.2 General messages

General messages Table D-1 below shows a number of general alarm/error messageswhich are not related to specific modules.

Table D-1 General, non module-specific messages

"APPLICATION NOT YET LOADED"

Reason Possible solution

1. The application has not been loadedinto the FSC system.

Use the "Download Software" option of the FSC Navigatorsoftware to download the application into the FSC system.

"JUMPER SETTING COM MODULE ON SYSTEM BUS NOT CORRECT"


1. The communication modules havebeen removed from the Central Partand have not been placed back atthe correct module position.

Check the placement of all Central Part modules accordingto the project-related documentation. Check the jumpersettings at the rear of the system bus.

2. A communication module has beenadded or removed, and the jumpersetting at the rear of the system bushas not been updated.

Check the jumper setting at the rear of the system bus.

Service Manual


D.3 Analog input module 10102/x/x

10102/x/x modules Table D-2 below shows the most common alarm/error messagesrelated to the 10102/x/x analog input modules.

Table D-2 Messages related to 10102/x/x analog input modules

"ANALOG INPUT SENSOR BREAK ALARM"


1. An analog input value exceeded itsspecified range. Use the "LoopStatus" option of FSC Navigator todetermine the tag number.

These analog input values arespecified in the "SystemConfiguration" option of FSCNavigator.

1. Use the "I/O Signal Status" option of FSC Navigator tocheck the analog input value. If it is within the specifiedrange, activate the FSC Reset key switch.

2. If the alarm message is generated frequently, use the"System Configuration" option of FSC Navigator tocheck the analog input setting. Please note that if thesesettings are modified, the new application should bereloaded into the FSC system.

3. If the problem persists, it might be advisable toexchange the field device.

"INPUT COMPARE ERROR"


1. A discrepancy was detectedbetween the analog inputs fromCentral Part 1 and Central Part 2.

1. Check the input for fast transients. An FSC systemreset is required to clear the message.

2. If the alarm message is generated frequently, it isadvisable to exchange both analog input modules.

Service Manual


D.4 Analog input module 10105/2/1

10105/2/1 module Table D-3 below shows the most common alarm/error messagesrelated to the 10105/2/1 analog input module.

Table D-3 Messages related to 10105/2/1 analog input module

"ANALOG INPUT SENSOR BREAK ALARM"


1. An analog input value exceeded itsspecified range. Use the "LoopStatus" option of FSC Navigator todetermine the tag number.

These analog input values arespecified in the "SystemConfiguration" option of FSCNavigator.

1. Use the "I/O Signal Status" option of FSC Navigator tocheck the analog input value. If it is within the specifiedrange, activate the FSC Reset key switch.

2. If the alarm message is generated frequently, use the"System Configuration" option of FSC Navigator tocheck the analog input settings. Please note that ifthese settings are modified, the new application shouldbe reloaded into the FSC system.

3. If the problem persists, it might be advisable toexchange the field device.

Service Manual


D.5 Analog output module 10205/2/1

10205/2/1 module Table D-4 below shows the most common alarm/error messagesrelated to the 10205/2/1 analog output module.

Table D-4 Messages related to 10205/2/1 analog output module

"ANALOG OUTPUT SCALING ERROR"


1. The engineering value calculated inthe FLDs forced the output of theanalog module to go below 0 mA orover 20 mA. This has caused theFSC system to stop.

Check the FLDs and modify them in such a way that theanalog output value can never exceed its minimum andmaximum values.

Service Manual


D.6 Communication errors with the FSC user station

Communicationerrors

Table D-5 below shows a number of errors that are reported ifcommunication between the FSC system and the user station cannotbe established.

Table D-5 No communication with the FSC system

"CHECK CONNECTION WITH FSC SYSTEM"


1. An incorrect on-line communicationport has been selected.

Use FSC Navigator (On-Line / Communication Port) tochange the communication port.

2. The communication cable is notconnected (correctly).

Check whether the communication cable is connected tothe FSC user station and to the correct FSC system.

3. The incorrect application has beenselected.

Use FSC Navigator (File / Open Project) to open thecorrect application.

4. EPROMs have been insertedincorrectly on a Central Part module.

Check the placement of the EPROMs on the Central Partmodules. Look for bent pins on the EPROMs.

5. Communication modules have notbeen correctly placed in the CentralPart.

Verify the placement of the communication modulesagainst the rack layout.

6. You are attempting to communicatewith a Central Part that has stopped.

Replace the communication cable to the Central Part whichis operational.

7. A communication module has notbeen correctly added.

Verify the placement of the communication modulesagainst the rack layout, and check whether the jumper atthe rear of the system bus has been removed.

Service Manual


D.7 Output short circuit

Outputshort circuit

Table D-6 shows the actions to be taken if an output short circuit isreported by the FSC system.

Table D-6 Output short circuit

"OUTPUT SHORT CIRCUIT"


1. The FSC system has detected anshort circuit output.

Use the on-line environment of FSC Navigator to checkwhether the short circuit has been resolved. If not, the shortcircuit needs to be solved. After resolving the short circuit,an FSC system reset is required.

Service Manual


D.8 Download not successful

Download notsuccessful

Table D-7 shows the most common errors when downloading wasnot successful.

Table D-7 Download not successful

"DOWNLOAD NOT SUCCESSFUL"


1. There is bad communication withFSC system via the FSC-FSCcommunication link.

Retry, or, if possible, try to load directly into the FSCsystem instead of via the FSC-FSC link.

2. The RAM size has changed but thehardware has not been modified.

Check the translation log file for the correct size of the RAMchips.

Service Manual


D.9 Process trip during an on-line modification

Process tripduring OLM

Table D-8 shows some possible causes if a process trip occurs duringan on-line modification.

Table D-8 Process trip

PROCESS TRIP DURING AN ON-LINE MODIFICATION


1. A sheet reference to a lower sheetnumber has been added (loopback).Due to the processing order of theFLD sheets, this lower on-sheetreference will be "0" during the firstapplication cycle.

Check whether any loopbacks of sheet references havebeen made. If so, update the FLD to prevent logic trips inthe future.

2. An output to an "AND" function wasset to low due to the fact that oneinput was missing. This was causedby a new input to this "AND"function.

Check the FLDs. If this situation can occur again, preventthis by adding logics.

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D.10 Calculation errors

Calculation errors Table D-9 shows some possible causes if a calculation error isreported.

Table D-9 Calculation errors

"CALCULATION OVERFLOW"


1. The output of a conversion blockexceeded the values of the outputsignal type. Due to this the FSCsystem stopped.

Check the FLDs for conversion blocks. Add logic to theconversion blocks which will prevent a calculation overflow.

"DIVIDE BY 0"


1. A division by 0 was attempted. Thishas caused the FSC system to stop.

Check the FLDs for division functions. Add logics in orderto ensure that the denominator will never be 0.

"ILLEGAL ARGUMENT, E.G. SQUARE ROOT OF –1"


1. A square-root function wasperformed on a negative value. Thishas caused the FSC system to stop.

Check the FLDs for square-root functions. Add logics to thesquare-root function in order to ensure that the value whichthe square root function will be performed on, will never bea negative number.

"ILLEGAL COUNTER VALUE (0..8191)"


1. The input value to a counter hasexceeded its range. This has causedthe FSC system to stop.

Check the FLDs for counters. Add logics to the counter inorder to ensure that the counter input will never exceed themaximum defined counter values.

Service Manual


Table D-9 Calculation errors (continued)

"ILLEGAL TIMER VALUE (0..2047)"


1. The value written to a timer variablegoes below 0 or over 2047. This hascaused the FSC system to stop.

Check the FLDs for timers. Add logics to the timer in orderto ensure that the timer input will never exceed themaximum defined timer values.

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Service Manual

Appendix E: Checklists 235

Appendix E – Checklists

E.1 Section overview

Section This appendix provides a number of checklists which can be usedduring preventive maintenance on an FSC cabinet.


E.1 Section overview........................................................................................... 235E.2 Preventive maintenance overview................................................................ 236E.3 Checklist for three-monthly maintenance ..................................................... 238E.4 Checklist for maintenance during power-down............................................. 241

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236 Appendix E: Checklists

E.2 Preventive maintenance overview

Preventivemaintenance

Preventive maintenance is necessary to prevent faults in the FSCcabinet. It is concentrated on the most sensitive elements in the FSCcabinet. The preventive maintenance that should be carried out can besplit 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 maintenancerefer to Section 7 of this Service Manual.

Checklists The checklists contained in subsections E.3 and E.4 allow you tokeep 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 andFSC cabinet which preventive maintenance is performed on.

FSC configurationitems

This section provides information on software versions, applicationversions, power-on mode, etc. This information can be retrievedusing the FSC user station (with FSC Navigator running on it).For details on how to retrieve this information refer to Section 7 ofthis Service Manual.

FSC systeminformation

This section provides information on Central Part voltages andtemperature sensors in the Central Part. For details on how to retrievethis information refer to Section 7 of this Service Manual.

Service Manual


Itemsto be checked

This section provides information on which items are to be checkedduring the preventive maintenance. For details refer to Section 7 ofthis Service Manual.

Conclusion /comments

This section contains general conclusions about the state of the FSCcabinet as identified during the maintenance performed.

Acceptance ofchecklist

After completion of the checks, the customer representative and theHoneywell SMS representative both sign the completed checklist.

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E.3 Checklist for three-monthly maintenance

Table E-1 Three-monthly maintenance checklist

General InformationCustomer: Date:

Plant name: FSC cabinet number:

Customer representative: FSC application name:

Customer reference number:

Honeywell representative:

Honeywell reference number:

FSC Configuration ItemsFSC software version: Application version:

Memory type: EPROM / RAM /FLASH

EPROM size CPU:

RAM size CPU:

512 Kb /1 / 2 / 4 Mb512 Kb / 1 / 4 Mb

Power-on mode: Cold / Warm start EPROM size COM: 512 Kb / 1 / 4 Mb

On-line modification: Yes / No Minimum execution time: ms

Maximum execution time: ms

FSC System InformationCentral Part 1 Central Part 2

Battery voltage S-Bus: Vdc Battery voltage S-Bus: Vdc

Battery voltage DBM: Vdc Battery voltage DBM: Vdc

Supply voltage: Vdc Supply voltage: Vdc

Temperature sensor 1: °C/°F/°K Temperature sensor 1: °C/°F/°K


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Table E-1 Three-monthly maintenance checklist (continued)

Items To Be CheckedAction Item: Checked

OK:Comments/Notes: Action

By:

A-1: Check the voltages to theCentral Parts.

A-2: Check the temperaturesin the Central Parts.

A-3: Check for obstruction ofair flow.

A-4: Check correct operationof fans.

A-5: Check for earth faults(if earth leak detection isavailable).

A-6: Check loop status ofsignals.

A-7: Check forced status ofsignals.

A-8: Check for paint damage.

A-9: Check availability ofspare parts.

A-10: Check the systemdiagnostics.

A-11: Check the backup of theFSC application files.

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Table E-1 Three-monthly maintenance checklist (continued)

Conclusion / CommentsItem: Conclusion / Comments Action

By:

Name of customerrepresentative:

Name of Honeywellrepresentative:

Signature: Signature:

Date: Date:

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E.4 Checklist for maintenance during power-down

Table E-2 Power-down maintenance checklist

General InformationCustomer: Date:

Plant name: FSC cabinet number:

Customer representative: FSC application name:

Customer reference number:

Honeywell representative:

Honeywell reference number:

FSC Configuration ItemsFSC software version: Application version:

Memory type: EPROM / RAM /FLASH

EPROM size CPU:

RAM size CPU:

512 Kb /1 / 2 / 4 Mb512 Kb / 1 / 4 Mb

Power-on mode: Cold / Warm start EPROM size COM: 512 Kb / 1 / 4 Mb

On-line modification: Yes / No Minimum execution time: ms

Maximum execution time: ms

FSC System InformationCentral Part 1 Central Part 2

Battery voltage S-Bus: Vdc Battery voltage S-Bus: Vdc

Battery voltage DBM: Vdc Battery voltage DBM: Vdc

Supply voltage: Vdc Supply voltage: Vdc



Service Manual


Table E-2 Power-down maintenance checklist (continued)



By:

B-1: Check the voltages to theCentral Parts.

B-2: Check the temperaturesin the Central Parts.

B-3: Check for obstruction ofair flow.

B-4: Check correct operationof fans.

B-5: Check for earth faults(if earth leak detection isavailable).

B-6: Check loop status ofsignals.

B-7: Check forced status ofsignals.

B-8: Check for paint damage.

B-9: Check availability ofspare parts.

B-10: Check the systemdiagnostics.

B-11: Check the backup of theFSC application files.

B-12: Check externally suppliedDC voltages. (List feederswith voltage levels.)

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By:

B-13: Check DC voltagesgenerated by PSUs inFSC cabinet. (List PSUswith voltage levels.)

B-14: Check fuses in powerdistribution wiring.

B-15: Check all AC voltages.(List feeders with voltagelevels.)

B-16: Check correct operationof all PSUs.

B-17: Check fans for dustconcentration.

B-18: Replace all dust filters.

B-19: Check the fasteners onthe power distributionunits.

B-20: Check all cable clamps.

B-21: Check all shieldconnections.

B-22: Check all earth/groundconnections.

B-23: Test all hardware I/O.

B-24: Test all communicationlinks with externaldevices.

Service Manual



Conclusion / CommentsItem: Conclusion / Comments Action

By:

Name of customerrepresentative:

Name of Honeywellrepresentative:

Signature: Signature:

Date: Date:

Service Manual

Appendix F: Using Ferrites 245

Appendix F – Using Ferrites

F.1 Section overview

Section This appendix provides information on the ferrites to be used for theAC and DC power/feeder cables. The ferrites only need to be added ifthey are not already installed in the FSC cabinet.


F.1 Section overview........................................................................................... 245F.2 Using ferrites................................................................................................. 246F.3 Ferrites on AC power/feeder cables ............................................................. 250F.4 Ferrites on DC power/feeder cables............................................................. 251

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246 Appendix F: Using Ferrites

F.2 Using ferrites

Use of ferriteson cables

Ferrites are used to filter out any electromagnetic interference (EMI)from the power/feeder cables.

The ferrites should preferably be of make Würth or Kitagawa, butequivalent ferrites may also be used. Table F-1 lists the recommendedWürth or Kitagawa ferrites with their characteristics. If ferrites otherthan Würth or Kitagawa are used, their impedance specificationsshould at least equal (or exceed) the values given in Table F-1.

Table F-1 Würth and Kitagawa ferrites and their characteristics

HSMSpart no.

Würthpart no.

Kitagawapart no.

Type(see Figure F-1)

Impedance at25 MHz (Ohm)

Impedance at100 MHz (Ohm)

Max. cablediameter

1 pass 2 wind. 1 pass 2 wind. mm in

4242011 742 7134 TRCN 28-16-20 A 79 324 160 683 15.8 0.62

4242012 742 7135 TRCN 40-27-15 A 48 197 98 382 26.5 1.04

4242013 742 7114 SFC-4 B* 101 411 144 534 5 0.20

4242019 742 7111 SFC-5 B 181 773 253 682 6 0.24

4242014 742 7122 SFC-10 B 155 650 273 744 12.5 0.49

4242015 742 7143 TFC-16-8-16 C 81 311 145 604 8.0 0.31

4242016 742 7140 TFC-20-10-10 C 55 202 98 421 9.0 0.35

4242017 742 7144 TFC-23-11-14 C 81 314 141 555 11.0 0.43

* This type of ferrite has the shape of an octagonal cylinder.

Figure F-1 Ferrite types

Service Manual


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 ifcable dimensions prohibit the use of a single ferrite to achieve therequired impedance. The total impedance will be the sum of theimpedance of the individual ferrites. Thus, the total impedance at25 MHz of two Würth 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-passferrite to achieve the required impedance. With this method, theferrite's total impedance increases by much more than a factor twocompared to the 'standard' method. For example, the totalimpedance at 25 MHz of one Würth ferrite, type 742 7134, with twocable windings is 324 Ohm (see Table F-1).

1 ferritesingle pass

(1sp)

2 ferritessingle pass

(2sp)

1 ferritedouble winding

(1dw)

Figure F-2 Ferrite layout

Note:After the ferrites have been installed, they must be closedcompletely and tightly. If the ferrite's core is not fully closed,its effect is minimal. You may want to use a tie wrap around theferrite to ensure that it remains firmly closed.

Service Manual


Example: Consider a situation in which the ferrite impedance of power supplycables must be at least 155 Ohm at 25 MHz and 273 Ohm at100 MHz (see Table F-1). The 'standard' ferrite to be used is Würthtype 742 7122 (or its Kitagawa counterpart), but if the cable diameterexceeds 12.5 mm (0.49 in), there are alternatives. The table belowlists the various options, with the 'alternative' ferrites italicized.

Table F-2 Ferrite selection (example)

Würthpart number

Impedance No. of ferrites req. withsingle pass (with

imp. at 25/100 MHz)

No. of ferrites req.with 2 windings (withimp. at 25/100 MHz)

at 25 MHz at 100 MHz

742 7122 155 273 1 (155 / 273) –

742 7134 79 160 2 in series (158 / 320) 1 (324 / 683)

742 7135 48 98 4 in series (192 / 392) 1 (197 / 382)

Service Manual


Ferrite selectiontable

Table F-3 below lists the types of ferrites that should be used forpower supply cables. A number of alternatives are provided, whichcan be used if the 'standard' is not an option due to cable sizelimitations. The 'alternative' ferrites are printed in italics.Subsections F.3 and F.4 contain illustrations that show how theferrites should be installed.

Table F-3 Ferrite selection table

Cable types Req. impedance Ferrite(s) used* Layout** Remark

25 MHz 100 MHz

Power cables:

24, 48, 60, 110, 220 Vdc or115, 230 Vac

155 273 Würth 742 7122Würth 742 7134Würth 742 7134Würth 742 7135Würth 742 7135Würth 742 7144

1sp2sp1dw4sp1dw2sp

see Figure F-3and Figure F-4

Notes:* 'Alternative' ferrites to the 'standard' ferrite are printed in

italics. These can be used if the 'standard' ferrite is not anoption due to excessive cable size.

** 1sp = single ferrite, single pass1dw = single ferrite, double winding2sp = two ferrites in series, single pass4sp = four ferrites in series, single pass2spdw = two ferrites in series, one with single pass and

one with double winding

Service Manual


F.3 Ferrites on AC power/feeder cables

Ferrites on ACpower/feeder cables

Ferrites on AC power/feeder cables should be installed as shown inFigure F-4.The ferrites should be placed as close as possible to the incomingpower/feeder fuse terminals and/or main circuit breaker.

Ferrite742 7112

Ferrite742 7112

Fuse terminals Main circuit breaker

Figure F-3 Ferrites on AC power/feeder cables

Service Manual


F.4 Ferrites on DC power/feeder cables

Ferrites on DCpower/feeder cables

Ferrites on DC power/feeder cables should be installed as shown inFigure F-4.

Ferrite742 7112

Ferrite742 7112

1030

6/./.

10306/./.

Figure F-4 Ferrites on DC power/feeder cables

Service Manual



Service Manual

Appendix G: Repair Handling and Ordering of Emergency Spare Parts 253

Appendix G – Repair Handling and Ordering of EmergencySpare Parts

G.1 Section overview

Section This appendix provides information on repair handling and orderingof emergency spare parts. It covers the following topics:


G.1 Section overview........................................................................................... 253G.2 Terminology .................................................................................................. 254G.3 Handling of defective products/parts ............................................................ 255G.4 Ordering of emergency replacements .......................................................... 257

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254 Appendix G: Repair Handling and Ordering of Emergency Spare Parts

G.2 Terminology

Terminology The following terminology is important:

Products Products are defined as hardware and/or software designed,manufactured and sold by Honeywell Safety Management Systems(HSMS).

Parts Parts are defined as single components from which products aremanufactured.

Defects Defects are defined as a non-functionality in a product and/or part

Repeatable defect Repeatable defect is defined as a non-functionality of a productand/or part which finds its origin in the design and/or manufacturingspecification.

Emergencyreplacements

Emergency replacements are products and/or parts required forreplacement of defective products and/or parts during the process of aFactory Acceptance Test (FAT) in Honeywell premises and fielddefects which need emergency exchange. The quantities foremergency replacements are typically small and parts may NOT beused for expansion/modification purposes!

Service Manual


G.3 Handling of defective products/parts

Handling defectiveproducts/parts

This section describes how defective products/parts are handled byHSMS.

Returning goods Defective products/parts can be returned to HSMS for repair.

Identification HSMS is the only repair center for the HSMS product/part within theHoneywell organization. The defective product/part shall be clearlyidentified 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 defectiveitem.

Analysis HSMS will analyze the returned product/part. Upon receipt HSMSwill 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 costestimate 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.

Service Manual


Invoices HSMS will invoice the sender if the warranty period for the part haselapsed:• For the amount of the repair cost (these costs will never exceed the

costs for a new module), and• The shipment costs.

Repair costestimate

Before a part is actually sent in for repair, a repair cost estimate maybe requested from HSMS.

Repairedproduct/part return

After a part has been repaired, it will be returned to the senderaddress unless there are specific shipping instruction to send itelsewhere.If the delivery address differs from the invoice address, a pro-formainvoice will be part of the delivery documents for custom clearancepurposes. A repair report will be a standard component of theshipment. All deliveries are ex works HSMS.

Time to repair Upon receipt of a defective part, a receipt notification will be issuedto the sender which includes an estimated time to repair.The normal repair cycle for FSC parts is four weeks after receipt atHSMS. The time to repair for non-FSC parts/equipment depends onthe repair cycles of their respective suppliers.

Emergencyreplacements

Emergency replacements can be ordered using the proceduredescribed in subsection G.4.

Service Manual


G.4 Ordering of emergency replacements

Orderingemergencyreplacements

This section describes how the ordering of emergency replacementsis handled by HSMS.

Requests Requests for emergency replacements must be communicated withHSMS.

Fax Requests for emergency replacements must be submitted to HSMS bymeans of a fax message which clearly indicates "EMERGENCYREPLACEMENT REQUEST". As a minimum, the fax must state thefollowing:• 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.

Shipment anddocuments

The shipment of the emergency replacement will be accompanied bya pro-forma invoice and a bill of lading stating that it is a repairreplacement for custom clearance. All deliveries are ex works HSMS.

Invoice An invoice will be sent to the requester based on the project price forthe part(s) requested, plus the shipping cost.

Credit note 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 berepaired.

Service Manual


Beyond repair If it turns out that a returned product/part cannot be repaired, therequester will be informed and no credit note will be submitted.

Warranty HSMS will check whether the returned item is still under warranty. Ifit is, a credit note of 100% of the price will be submitted.

Return of defectiveproduct/part The defective product/part must be returned to HSMS.

READER COMMENTSHoneywell Safety Management Systems welcomes your comments and suggestions to improve future editions of thisand other documents.

You can communicate your thoughts to us by fax or mail using this form, or by sending an e-mail message. We wouldlike 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 [email protected]

BY MAIL: Use this form and mail to us at:Honeywell Safety Management Systems B.V.Attn. Marketing DepartmentP.O. Box 1165201 AC 's-HertogenboschThe Netherlands

Title of Document: Fail Safe Control Issue Date: 03/2000Service ManualRevision 03

Document Number: FS99-504 Writer: HSMS Product Marketing

COMMENTS:

RECOMMENDATIONS:

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Fs 99504

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