B0193ad R

B0193AD
REV R
I/A Series®
System Maintenance
November 4, 2004
Invensys, Foxboro, I/A Series, INTERSPEC, SPEC 200, SPECTRUM, and UFM are trademarks of Invensys
plc, its subsidiaries, and affiliates.
Modicon and Modbus are trademarks of AEG Schneider Automation, Inc.
PC-TRAC is a trademark of Microspeed, Inc.
PostScript is a trademark of Adobe Systems, Inc.
Solaris and SunOS are trademarks of Sun Microsystems, Inc.
TAPEPORT and Wangtek are trademarks of Wangtek, Inc.
VENIX is a trademark of VenturCom, Inc.
VT-100 is a trademark of Digital Equipment Corporation.
WYSE is a trademark of Wyse Technology.
All other brand names may be trademarks of their respective owners.
Copyright 1990-2004 Invensys Systems, Inc.

All rights reserved
Contents
Figures.................................................................................................................................... ix
Tables..................................................................................................................................... xi
Preface................................................................................................................................. xiii
Maintenance Philosophy ........................................................................................................ xiii
Revision Information ............................................................................................................. xiii
Reference Documents ............................................................................................................ xiii
Hazardous Location Precautions (CSA Requirements) ........................................................... xiv
1. Preventive Maintenance .................................................................................................... 1

Enclosures ................................................................................................................................. 1
Industrial Enclosures 16/32 – Air Filters .............................................................................. 1
Metal Enclosures (Vented) – Air Filters ................................................................................ 1
Modular Industrial Workstations .............................................................................................. 2
Monitor-Based Peripheral Devices ............................................................................................ 2
Printers ..................................................................................................................................... 3
Keyboard ................................................................................................................................... 3
Mouse ....................................................................................................................................... 3
Data Storage Devices ................................................................................................................. 4
120 MB Hard Disk Drive – Air Filter ....................................................................................... 4
Trackball ................................................................................................................................... 5
Wangtek TapePort Drive .......................................................................................................... 5
Head Cleaning ..................................................................................................................... 6
Drive Capstan Cleaning ....................................................................................................... 6
2. Fault Analysis .................................................................................................................... 7

Startup Diagnostics ................................................................................................................... 7
Startup Diagnostic Tests ...................................................................................................... 7
Operator Procedures for Fault Analysis Tasks ............................................................................ 8
Fault Tests ................................................................................................................................ 9
On-line Diagnostics ............................................................................................................. 9
Test Procedure ................................................................................................................ 9
Nodebus Cable Test Loopback Message Reporting ....................................................... 13
Off-line Diagnostics ........................................................................................................... 15
Station Diagnostic Tests ..................................................................................................... 18
Communication Processor 10 and 760/761 Gateway .................................................... 18
iii
B0193AD – Rev R Contents
Communication Processor 15/30, INIs, and Gateways .................................................. 18

Control Processor 10, 30, and 40 .................................................................................. 19
Application Processor 20 ............................................................................................... 20
Workstation Processor 30 .............................................................................................. 21
SPECTRUM Slave Gateway ......................................................................................... 21
Tank Processor 10 ......................................................................................................... 22
Carrierband LAN Interface ............................................................................................ 23
INTERSPEC Integrator ................................................................................................ 25
Station Performance Tests ....................................................................................................... 25
Explanation of System Event Counters ............................................................................... 29
Station Status Displays ............................................................................................................ 36
Fault Location Tables ......................................................................................................... 38
Station Equipment Changes – Fault Location Table ...................................................... 39
Peripheral Equipment Changes – Fault Location Table ................................................. 41
Station Equipment Information – Fault Location Table ................................................ 43
Peripheral FBP10 (Fieldbus Cluster I/O Subsystem) – Fault Location Information ....... 46
Peripheral FBP11 Through FBP14 (SPECTRUM Control Integrator) –
Fault Location Information ........................................................................................... 46
Peripheral FBM Information – Fault Location Table .................................................... 46
Intelligent Field Device Information – Fault Location Table ......................................... 48
HIU Information – Fault Location Table ...................................................................... 52
FD Gateway Peripheral Information – Fault Location Table ......................................... 55
INTERSPEC Integrator Translator Information – Fault Location Table ....................... 56
INTERSPEC AIM Peripheral Information – Fault Location Table ............................... 57
INTERSPEC UIO Peripheral Information – Fault Location Table ............................... 59
Allen-Bradley Peripheral Information – Fault Location Table ........................................ 61
Allen-Bradley Redundant ECB Information – Fault Location Table ............................. 63
Allen-Bradley Station Equipment Information – Fault Location Table .......................... 64
Allen-Bradley Station Rack Equipment Information – Fault Location Table ................. 66
INI 15 Information – Fault Location Table ................................................................... 67
WP50/WP51 Peripheral Information – Fault Location Table ....................................... 68
Peripheral Printer/Terminal Information – Fault Location Table .................................. 70
Memory Parity Errors and I/A Series Station Response ...................................................... 71
Memory Parity Errors .................................................................................................... 71
I/A Series Station Response to Parity Errors ................................................................... 72
I/A Series FBM Response to Memory Parity Errors ....................................................... 72
3. Corrective Maintenance................................................................................................... 73
Module Status Indicators ........................................................................................................ 73
Power, Processor, and Fieldbus Modules ............................................................................ 73
DNBI/DNBT/DNBX Modules ......................................................................................... 73
LAN Z-Modules ................................................................................................................ 74
Fiber Optic Nodebus Extender Module ............................................................................. 75
AP20 Module ..................................................................................................................... 76
Reset Switch .................................................................................................................. 77
120 MB Hard Disk Module ............................................................................................... 77
I/A Series Module Replacement .............................................................................................. 77
iv
Contents B0193AD – Rev R
FBM Replacement using the Output Bypass Station .......................................................... 77

I/O Static Discrete Submodule Replacement .......................................................................... 79
IPM06A and IPM06D Battery Care ....................................................................................... 80
Battery Charge/Recharge Procedures .................................................................................. 81
Normal Maintenance ......................................................................................................... 81
IPM06A and IPM06D Modules Not Immediately Placed Into Service .............................. 81
Reinstallation of IPM06A and IPM06D Into Backup Service ............................................ 82
IPM06A and IPM06D Battery Replacement ........................................................................... 82
Battery Replacement Kit ..................................................................................................... 82
Equipment Required .......................................................................................................... 82
Battery Removal/Replacement Procedure for P/N CM902WX/WY ................................... 83
De-energizing Existing Battery ...................................................................................... 83
Removal and Replacement of Existing Battery ............................................................... 83
IPM7, 8, 9 Fan Power Module Replacement .......................................................................... 84
Fan and Grill Assembly Replacement ...................................................................................... 85
Junction Box Circuit Breaker Replacement ............................................................................. 87
Letterbug Replacement ....................................................................................................... 88
AP20 Data Storage Device Replacement ............................................................................ 89
Mounting Structure Bus Replacement .................................................................................... 89
Fault-Tolerant Processor Module Replacement ....................................................................... 90
Rear-Mounted Fault-Tolerant Module Connector Replacement ............................................. 90
Front-Mounted Fault-Tolerant Module Connector Replacement ........................................... 91
Pin Assignments for the Input Power Bus ............................................................................... 92
Input Wiring Configuration for Input Power Modules ........................................................... 93
Processor Module Troubleshooting Guide .............................................................................. 96
Single Module Not Rebooting ............................................................................................ 96
Application Processor 20 Not Rebooting ............................................................................ 97
Modules Hosted by an AP Not Rebooting ......................................................................... 97
AP Boots, One or More Stations Not Rebooting ................................................................ 97
Nodebus Extender Failure .................................................................................................. 98
General Module Failure ...................................................................................................... 98
Station Uploads .................................................................................................................. 98
Customer Actions After an Upload ................................................................................ 98
AP20 Uploads ............................................................................................................... 98
CP30/40 and WP30 Uploads ........................................................................................ 99
All Other Station Type Uploads .................................................................................. 100
Notifying Foxboro of Uploads ..................................................................................... 100
Disabling Uploads ....................................................................................................... 100
Module Going From Green State to Red/Green State ...................................................... 100
Problem Caused by Station Not Contained in any Domain ............................................. 101
Fault-Tolerant Troubleshooting Guide ................................................................................. 101
Fault-Tolerant CP Operation, General Information ......................................................... 101
Fault-Tolerant Pair; One Fails .......................................................................................... 101
v
CP10(s) Not Married ....................................................................................................... 102

AP20(s) Not Married ....................................................................................................... 102
LI(s) Not Married ............................................................................................................ 103
Network Fault Detection ................................................................................................. 103
Replacement of FT Modules While Both Are in Off–line Diagnostics ............................. 104
LAN Interface Modules .................................................................................................... 104
LAN Interface LEDs Red/Green and System Management Indicating Failure ............. 104
Notes on LAN Z-Module LED Indicators ................................................................... 104
Fieldbus Module (FBM) Troubleshooting Guide .................................................................. 105
FBM With or Without Expansion Module, Does Not Boot (Red/Green LEDs On) ........ 105
All FBMs in an Enclosure Fail, (No LEDs On) ................................................................ 106
FBM Without Expansion Module Fails, (Red LED On) .................................................. 106
FBM With Expansion Module Fails (Main Red/Green LEDs On; Ext LED Red On) ..... 106
FBM With Expansion Module Fails (Main Red/Green
LEDs On; Expansion LED Red Off) ................................................................................ 107
FBM Main and Expansion Module Fail, (No LEDs On) ................................................. 107
“No Such File or Directory /usr/fox/sysmgm/softmgr/file/sm_lth_lc” Error Message ....... 108
Loss of FBM Status Messages ........................................................................................... 108
FBM04, FBM06, FBM44 (Redundant AO) Maintenance Procedure ............................... 108
FBM05 and FBM46 Maintenance Procedure ................................................................... 108
Human Interface Troubleshooting Guide ............................................................................. 108
WP Locks Up (Touchscreen Inoperative) ......................................................................... 108
WP Displays Frozen with Peripherals Operative ............................................................... 109
Input/Output Data Loss on Displays ............................................................................... 110
Touchscreen Calibration Procedure .................................................................................. 110
Rebooting a WP ............................................................................................................... 111
Keypanels, Annunciator Keyboards .................................................................................. 111
GCIO Firmware (Touchscreen) ....................................................................................... 111
“smdhspf_serv IPC-1041” Error Message ......................................................................... 111
Alarm Horn Operation .................................................................................................... 111
Failure to Unmount Remote File Systems ........................................................................ 111
Printer Troubleshooting Guide ............................................................................................. 112
Buffer Full – No Output on Printer ................................................................................. 112
AP Disk Full – Printer Files .............................................................................................. 113
Determining Printer Status .............................................................................................. 113
Checking on the Status of Your Print Requests ............................................................ 113
Checking on Available Printers .................................................................................... 114
Displaying All Status Information ............................................................................... 114
Displaying Status for Printers ...................................................................................... 114
Summary Table of lpstat Options ..................................................................................... 115
Canceling a Print Request ................................................................................................ 115
Canceling a Print Request by ID Number ................................................................... 116
Canceling a Print Request by Printer Name ................................................................ 116
Accepting/Rejecting Print Requests .................................................................................. 116
Accepting Print Requests ............................................................................................. 116
Rejecting Print Requests .............................................................................................. 116
Enabling/Disabling a Printer ............................................................................................ 117
vi
Contents B0193AD – Rev R
Enabling a Printer ........................................................................................................ 117

Disabling a Printer ....................................................................................................... 117
Starting/Stopping the Print Service Scheduler .................................................................. 118
Starting the Print Service Scheduler ............................................................................. 118
Stopping the Print Service Scheduler ........................................................................... 119
AP50 with Printer ............................................................................................................ 120
Printing a Header Page with lp ......................................................................................... 120
Print Device Failure After Alarm “Burst” Condition ........................................................ 120
Multiple Printscreen Requests Caution ............................................................................ 120
Nodebus Troubleshooting Guide .......................................................................................... 120
Reattaching a Nodebus ..................................................................................................... 121
Fiber Optic Nodebus Extension Troubleshooting Guide ...................................................... 121
Diskette Drives and SCSI Controller for the AP20 ............................................................... 121
Sony 20-Inch Display (with or without Touchscreen) ........................................................... 122
FBM Memory Parity Error Rates for I/A Series Stations ....................................................... 122
Module Replacement Policy for Hard Parity Error Failures .............................................. 123
Index .................................................................................................................................. 125
vii
viii
Figures
1-1. 120 MB Hard Disk Drive – Air Filter ........................................................................... 5
2-1. Carrierband LAN Display ........................................................................................... 11
2-2. Nodebus Display ......................................................................................................... 11
2-3. Carrierband LAN On-line Diagnostics Display ........................................................... 12
2-4. Nodebus On-line Diagnostics Display ........................................................................ 12
2-5. PIO Bus Display ......................................................................................................... 13
2-6. Off-line Diagnostics Display, Typical ......................................................................... 17
2-7. Off-line Diagnostics, Communication Processor 15, INI(s), and Gateways ................. 17
2-8. Off-line Diagnostics, Control Processors 10, 30, and 40 ............................................. 20
2-9. Off-line Diagnostics, Application Processor 20 ........................................................... 21
2-10. Off-line Diagnostics, SPECTRUM Slave Gateway ...................................................... 22
2-11. Off-line Diagnostics, TP10 ......................................................................................... 23
2-12. Off-line Diagnostics, Carrierband LAN Interface ........................................................ 24
2-13. Off-line Diagnostic Results Display (Typical) ............................................................. 24
2-14. Performance Options Display ..................................................................................... 26
2-15. System Management Counter Categories Display ....................................................... 26
2-16. MAC Sublayer Counters Display ................................................................................ 28
2-17. Peripheral Names and Types Display (Control Processor) ........................................... 28
2-18. Peripheral Counters (FBM) ......................................................................................... 29
2-19. Station Configuration Display (with FBM44 selected) ................................................ 37
2-20. Station Change Options Display ................................................................................. 39
2-21. Peripheral Change Options Display ............................................................................ 41
2-22. Equipment Information Display for Station ................................................................ 43
2-22. Equipment Information Display for Station (Continued) ........................................... 44
2-23. Equipment Information Display for FBM ................................................................... 46
2-23. Equipment Information Display for FBM (Continued) .............................................. 47
2-24. Equipment Information Display for Intelligent Transmitter ....................................... 48
2-24. Equipment Information Display for Intelligent Transmitter (Continued) ................... 49
2-24. Equipment Information Display for Intelligent Transmitter (Continued) ................... 49
2-25. Equipment Information Display for HIU ................................................................... 54
2-25. Equipment Information Display for HIU (Continued) ............................................... 54
2-26. Equipment Information Display for Device Integrator Peripherals .............................. 55
2-27. Equipment Information Display for INTERSPEC Integrator Translator .................... 57
2-28. Equipment Information Display for INTERSPEC AIM Peripheral ............................ 58
2-28. Equipment Information Display for INTERSPEC AIM Peripheral (Continued) ........ 58
2-29. Equipment Information Display for INTERSPEC UIO Peripheral ............................ 60
2-29. Equipment Information Display for INTERSPEC UIO Peripheral (Continued) ........ 61
2-30. Equipment Information Display for Allen-Bradley Peripheral ..................................... 63
2-31. Equipment Information for Allen-Bradley Redundant Gateway .................................. 64
2-32. Equipment Information Display for Allen-Bradley Station PLC-5 Series Peripheral .... 66
2-33. Equipment Information Display for Allen-Bradley Station Rack ................................. 67
2-34. Equipment Information Display for INI 15 ................................................................ 68
2-35. Equipment Information Display for WP51 Peripherals ............................................... 69
2-35. Equipment Information Display for WP51 Peripherals (Continued) .......................... 70
ix
B0193AD – Rev R Figures
2-36. Equipment Information Display for Printer/Terminal ................................................ 71

3-1. LAN Module Status Indicator Location ...................................................................... 75
3-2. Application Processor 20 Z-Module ............................................................................ 76
3-3. Connection of Output Bypass Stations to FBM .......................................................... 79
3-4. Disconnecting Positive Battery Lead IPM06A (CM902WX), IPM06D (CM902WY) 81
3-5. Removing the Rechargeable Battery IPM06A (CM902WX), IPM06D (CM902WY) . 83
3-6. Fan Power Module and Fan Assembly ......................................................................... 86
3-7. Field Enclosure 8 (Metal) Fan Assembly Removal ....................................................... 86
3-8. Industrial Enclosure 16, Junction Box Locations ......................................................... 88
3-9. Field Enclosure 8 (Metal) Junction Box Location ........................................................ 88
3-10. Front-Mounted Fault Tolerant Module Connector Replacement ................................ 92
3-11. 100 and 120 V ac Input Power Bus Wiring Diagram .................................................. 93
3-12. 220 and 240 V ac Input Power Bus Wiring Diagram .................................................. 94
3-13. 24 and 125 V dc Input Power Bus Wiring Diagram ................................................... 94
3-14. Power Module 100/120 V ac Input Circuits ............................................................... 95
3-15. Power Module 220/240 V ac Input Circuits ............................................................... 95
3-16. Power Module 24/125 V dc Input Circuits ................................................................. 96
x
Tables
1-1. TapePort Tape Drive Recommended Preventive Maintenance Schedule ....................... 6
2-1. FBM Startup Diagnostics .............................................................................................. 8
2-2. Peripheral Interface Startup Diagnostics ........................................................................ 8
2-3. Cable Faults Truth Table ............................................................................................ 14
2-4. Communication Processor 10 and 760/761 Gateway Diagnostics ............................... 18
2-5. Communication Processor 15/30, INIs, and Gateways Diagnostics ............................ 19
2-6. Control Processor Diagnostics ..................................................................................... 19
2-7. AP20 Diagnostics ........................................................................................................ 20
2-8. WP30 Diagnostics ...................................................................................................... 21
2-9. SPECTRUM Slave Gateway Diagnostics .................................................................... 21
2-10. Tank Processor 10 Diagnostics .................................................................................... 22
2-11. Carrierband LAN Interface Letterbug Diagnostic ........................................................ 23
2-12. Diagnostic Test for INTERSPEC Integrator ............................................................... 25
2-13. MAC Sublayer Counters ............................................................................................. 30
2-14. Transport Layer Counters ........................................................................................... 31
2-15. Application Layer Counters ......................................................................................... 33
2-17. Station Loading Counters ........................................................................................... 35
2-16. Network Layer Counters, LI Only .............................................................................. 35
2-18. Peripheral Counters .................................................................................................... 36
2-19. Station Equipment Changes – Fault Location ............................................................. 39
2-20. Peripheral Equipment Changes – Fault Location ........................................................ 41
2-21. Station Equipment Information – Fault Location ....................................................... 44
2-22. Peripheral FBM Information – Fault Location ............................................................ 47
2-23. Intelligent Field Device Information – Fault Location ................................................ 50
2-24. HIU Information – Fault Location ............................................................................. 53
2-25. FD Gateway Peripheral Information – Fault Location ................................................ 55
2-26. INTERSPEC Integrator Translator Information – Fault Location .............................. 56
2-27. INTERSPEC AIM Peripheral Information – Fault Location ...................................... 59
2-28. INTERSPEC UIO Peripheral Information – Fault Location ...................................... 59
2-29. Allen-Bradley Peripheral Information – Fault Location ............................................... 62
2-30. Allen-Bradley Redundant ECB Information – Fault Location ..................................... 63
2-31. Allen-Bradley Station Equipment Information – Fault Location ................................. 65
2-32. Allen-Bradley Station Rack Equipment Information – Fault Location ........................ 66
2-33. INI 15 Information – Fault Location .......................................................................... 68
2-34. WP50/WP51 Peripheral Information – Fault Location ............................................... 69
2-35. Peripheral Printer/Terminal Information – Fault Location .......................................... 71
3-1. Status Indicators .......................................................................................................... 73
3-2. FONBE Module ......................................................................................................... 75
3-3. IPM06 (A, D) Battery Replacement Kit ...................................................................... 82
3-4. Printer Modes – XON/XOFF and Ready/Busy ......................................................... 113
3-5. Summary of Frequently Used lpstat Options ............................................................. 115
3-6. Options to the Disable Command ............................................................................ 117
3-7. Parity Error Rates for I/A Series Stations ................................................................... 122
xi
B0193AD – Rev R Tables
xii
Preface
This document provides maintenance and fault analysis procedures for the purpose of maintain-
ing the health and performance of your system. These instructions are an aid to the maintenance
personnel involved in servicing the system. The maintenance levels covered in this document are:
Preventive Maintenance – The purpose of this chapter is to guide maintenance personnel
through visual scheduled inspections, cleaning, lubrication, and adjustment of the system equip-
ment in order to extend the time between failures. The section contains the preventive mainte-
nance requirements for maintaining I/A Series enclosures, workstations, control and I/O
modules, and peripheral devices, including a Personal Workstation (PW).
Fault Analysis – This chapter contains a series of diagnostic procedures which allow you to per-
form tests and check procedures on the I/A Series components through the use of the I/A Series
system Management Service software. This service software enables you to monitor the health and
performance of the components, and locate the source of a fault to a replaceable control processor
module, Fieldbus Module, or peripheral device.
Corrective Maintenance – The steps in this chapter are used in response to a system failure. Cor-
rective maintenance analyzes the failure, locates the defect, and repairs through adjustment or
module replacement. It also allows diagnostic scheduling of the system, enabling the performance
of diagnostic tests on the system, network and stations, then, if necessary, applying corrective
maintenance actions.
Maintenance Philosophy
The maintenance approach is oriented toward module replacement. The use of diagnostics, fault
location tables, and troubleshooting guides described in this document, as well as the presence of
status lamps (LEDs) on each module, enables isolation of problems to the module level. In addi-
tion, any module can be replaced without affecting the operation of any other module, including
the module of a fault-tolerant pair.
Revision Information
For Release 6.5.2/7.1.1, the following changes were made:
♦ In Table 2-13, changes were made to 802.3 MAC RESETS entry.
♦ A correction was made in step 6 of “Removal and Replacement of Existing Battery”
on page 83.
♦ In Table 3-3, changes were made to the first row.
Reference Documents
System Equipment Installation – B0193AC
This document describes pre-installation considerations, equipment mounting, module
and peripheral device installation, inter- and intra-enclosure cabling, and initial power-up
procedures.
xiii
B0193AD – Rev R Preface
Site Planning – B0193AB

This document contains information on the following areas: equipment dimensions,
required clearances, power requirements, conduit entry, cable lengths, panel cutouts, envi-
ronmental requirements, fire and safety precautions, and shipping and handling consider-
ations.
Hardware Descriptions – B0193AE
This document describes the physical characteristics of the system hardware and peripher-
als, enclosures, mounting structures, and modules, as well as field wiring, terminators, and
power distribution. The document also describes the functional characteristics of the bus-
ses, modules, and interfaces.
System Configurator – B0193JH
This document describes how you select and define the hardware and software for your
system. When you complete the configuration process, you should generate a diskette that
defines the network, specifies the packaging, generates a list of materials for the quotation
system, documents the configuration, enables software, and enables installation.
Network Cable Systems Planning – B0193UX
Network Cable Systems Installation and Maintenance – B0193UW
System Operations Guide – B0193CR
System Management Displays – B0193JC
Integrators for Allen-Bradley Controllers – B0193RG
Allen-Bradley Station – B0193MK
Integrators for Modbus and Modbus Plus Devices – B0193RL
Measurement Integration – B0193RA
Fieldbus Cluster I/O User’s Guide – B0193RB
SPECTRUM Migration Integrator User’s Guide – B0193RC
System Definition: A-Step-By-Step Procedure – B0193WQ
HP Deskjet 1200C/PS Printers User’s Guide
AMT Accel-535 Operating Guide
Hazardous Location Precautions (CSA Requirements)

The precautions described herein must be observed when servicing the I/A Series equipment that
is certified for use in Class I, Division 2 locations. (The applicable equipment is identified else-
where within this document.)
NOTE
“Class I, Division 2” refers to Class I, Groups A, B, C, and D, Division 2; Class II,
Group G, Division 2 and Class III, Divisions 1 and 2: Hazardous locations (per
Canadian Electrical Code, Part 1, 1990).
Three servicing categories require compliance with the precautions that follow, these are:
♦ Equipment repair
xiv
Preface B0193AD – Rev R
♦
Component replacement
♦ Power supply disconnection
Where repair of the equipment is possible:
! WARNING
Explosion hazard – Substitution of components can impair suitability for Class I,
Division 2.
NOTE
AVERTISSEMENT: Risque d’explosion – la substitution de composants peut ren-
dre ce matériel inacceptable pour les emplacements de Classe I, Division 2.
Where replacement of a component could ignite the explosive atmosphere:
! WARNING
Explosion hazard – do not replace the component(s) unless power has been
switched off or the area is known to be non-hazardous.
NOTE
AVERTISSEMENT: Risque d’explosion – couper le courant ou s’assurer que
l’emplacement est designé non dangereux avant de remplacer les composants.
Where disconnecting the power supply could ignite the explosive atmosphere:
! WARNING
Explosion hazard – do not disconnect equipment unless power has been switched
off or the area is known to be non-hazardous.
NOTE
AVERTISSEMENT: Risque d’explosion – avant de déconnecter l’équipement,
couper le courant ou s’assurer que l’emplacement est désigné non dangereux.
xv
B0193AD – Rev R Preface
Pb
ATTENTION:
The product you have purchased contains a rechargeable battery.
The battery is recyclable. At the end of its useful life, under various state
and local laws, it may be illegal to dispose of this battery into the municipal
waste stream. Check with your local solid waste officials for details in your
area for recycling options or proper disposal methods.
xvi
1. Preventive Maintenance
This chapter guides maintenance personnel through visual scheduled inspections, cleaning,
lubrication, and adjustment of the system equipment in order to extend the time between
failures. The section contains the preventive maintenance requirements for maintaining
I/A Series enclosures, workstations, control and I/O modules, and peripheral devices, including
a Personal Workstation (PW).
The design of the I/A Series equipment and associated peripheral devices is such that scheduled
preventive maintenance on the equipment is limited to visual inspections, periodic cleaning pro-
cedures, and adjustment of system modules if necessary. While performing these routines, you
should check for damaged cables, loose connections, inoperative fans and indicator lamps, wear or
binding of drives and fan motors, and take appropriate corrective action.
Enclosures
Perform a general visual inspection and exterior cleaning of each enclosure after the first
six months of service. Approximately every 12 months thereafter perform the same, depending on
local environmental conditions. Preventive maintenance procedures for enclosures include the fol-
lowing:
1. Wipe down the exterior of the enclosure with a soft cloth. A damp cloth and/or a non-
abrasive cleaner can be used for hard-to-remove spots.
2. Clean any dust buildup from module heat fins. Use a soft cloth. If heat fins are acces-
sible from rear of enclosure, they can be cleaned during normal operation. Otherwise,
modules can be removed and cleaned from front of enclosure during routine equip-
ment shutdowns.
3. Check fans (if installed) for proper operation.
4. Check module status indicators for proper operation.
Green light indicates normal operation.
Red light indicates faulty operation.
Industrial Enclosures 16/32 – Air Filters

The vented configurations of the IE16 and IE32 enclosures have an air filter located inside the
door, behind the vents. Periodically check the condition of the filter for dust/dirt accumulation.
Replace the filter by sliding it up against the top retainer rail, and lifting it out over the bottom
retaining rail.
Metal Enclosures (Vented) – Air Filters

The vented configurations of all metal enclosures have an air filter located inside the door, behind
the vents. Periodically check the condition of the filter for dust/dirt accumulation. Perform the
following steps to check the condition of the filter:
1. Locate the plastic assembly that retains the filter that is on the inside of the door
behind the vents.
1
B0193AD – Rev R 1. Preventive Maintenance
2. Unsnap the plastic assembly from the vents and remove the filter.
3. Wash and replace the filter, or if desired, install a new filter, and snap the filter retainer
assembly back onto the vent assembly.
Perform an overall visual inspection and exterior cleaning of each chassis and chassis expander
after the first six months of service. Do the same every 12 months thereafter depending on the
severity of environmental conditions.
Modular Industrial Workstations

Perform a general visual inspection and exterior cleaning of each workstation as often as necessary
to ensure proper operation of the equipment. Preventive maintenance procedures for the worksta-
tions should include the following:
1. Wipe down the exterior of the enclosure with a soft cloth. A damp cloth and/or a non-
abrasive cleaner can be used for hard-to-remove spots.
2. Clean any dust buildup on disk drives (especially the signal connection areas), key-
boards, control panels, and monitors. Use a soft cloth.
3. Check fans (if installed) for proper operation.
4. Check module status indicators for proper operation.
Green light indicates normal operation.
Red light indicates faulty operation.
Monitor-Based Peripheral Devices

Monitor-based peripheral devices include the 20-inch Workstation and 20-inch table-top dis-
plays, the VT100 Compatible Terminal, and the Personal Workstation display. As a rule, preven-
tive maintenance on these devices should be limited to cleaning only and should be performed as
often as necessary, or at least every twelve months.
Wipe down the exterior of the device (excluding the monitor) with a soft cloth. A damp cloth
and/or nonabrasive cleaner can be used for hard-to-remove spots.
To clean the monitor, proceed as follows:
! WARNING
When the monitor is powered off, the touchscreen, mouse, and keyboard remain
active. The GCIO box powers the touchscreen but cannot be powered off because
the annunciators are connected to it. To prevent unwanted changes to the process,
perform the following procedure.
1. Select a screen that does not have direct access to the process, for example, the Initial
display.
2. Remove power from the GCIO unit (annunciators are also deactivated).
3. Turn the monitor’s power off. Do not move the mouse or depress any keys while the
monitor is off.
4. Dampen – do not saturate – a clean, lint-free cloth with liquid glass cleaner.
2
1. Preventive Maintenance B0193AD – Rev R
5. Clean the screen by wiping with damp cloth, using circular wiping motion to avoid
streaks.
6. Carefully dry the screen by wiping with a second clean, lint-free cloth.
7. Restore power to the monitor and GCIO.
Printers
All printers should be serviced every six months (or after 300 hours of operation), whichever
occurs first. Refer to the associated printer user’s guide (packed with the printer) and perform the
following:
1. Perform a general visual inspection and cleaning of the printer.
2. Remove printer cover and inspect internal moving parts for signs of wear, broken or
loose parts, frayed cables, and so on.
! WARNING
To prevent shock hazard, shut down the printer before proceeding.
3. Take a clean, dry, soft cloth and dust the area around carriage shaft and platen.
Remove any loose particles of paper and dust.
4. Lubricate printer as described in associated service instructions.
5. Restore printer power.
Keyboard
A keyboard should be cleaned at a frequency determined by the environment in which it is used.
1. Use a soft, lint-free cloth dampened with a mild detergent solution to clean the keys
and large surfaces.
2. Clean confined areas between the keys with a vacuum cleaner equipped with a fine
brush attachment.
Mouse
The following care and cleaning procedure applies to both the inner and outer area of the mouse:
1. The mouse is a very precise mechanical device, so handle it with care. Do not drop,
hit, or otherwise subject it to shock.
2. Do not pull on the cable. It may cause damage to both the cable and connector.
3. Do not carry the mouse by holding onto the cable.
4. Be sure to place a clean sheet of paper or use a mouse pad between the mouse and the
flat surface. Dirt and grit could collect on the ball. Try not to touch the ball on the
bottom.
5. Do not use the mouse in extreme temperatures (high or low) or in direct sunlight.
6. Do not allow the mouse to come in contact with liquid spills (water, solutions, and so
forth).
3
7. The mouse housing should be cleaned with a lint-free cloth using a mild detergent.
Use an unsoiled lint-free cloth to dry housing.
8. Do not disassemble the mouse. If the ball in the unit needs to be cleaned, remove it
from the lower case by detaching the cover to the housing. Do not remove all the
screws to remove the ball.
9. Use a lint-free cloth with mild detergent to clean the ball, and an unsoiled cloth to dry
it.
Data Storage Devices

1. Blow away any lint or dust accumulation on or near the face of the floppy disk and
streaming tape drive casings.
2. Clean the outer plastic surface of the drive with a lint-free cloth or a sponge slightly
dampened with water. Wipe off residue and dry with soft, lint-free cloth. Do not use
abrasive cleaners, solvents, or strong detergents.
3. Blow away any lint or dust accumulation on the signal and power connectors at the
rear of the drive.
4. For the streaming tape drive, clean the head using only Freon TF and polyurethane
swabs, commonly available with VCR head cleaning kits. Wet the swab with the
Freon TF solution, and wipe the head using an up and down motion. Use a dry swab
to clean any remaining residue from the head.
120 MB Hard Disk Drive – Air Filter

The 120 MB Hard Disk Drive, shown in Figure 1-1, is a single width Z-Module SCSI device for
use in AP20 configurations (using I/A Series Release 3.2 Software). The module contains a
sponge-type, washable air filter. Check the filter for dust accumulation monthly, or more fre-
quently in a dusty environment. The module does not have to be removed from its mounting
structure.
To clean the filter, perform the following steps:
1. Pinch the top of the bezel between your thumb and finger, and gently pull the top of
the bezel out away from the module, and down as shown.
2. Remove the filter, wash it in clean water, squeeze it dry, and replace it in the module.
3. Gently latch the top of the bezel back in place.
4
1. Preventive Maintenance B0193AD – Rev R
Filter
Pinch bezel with

thumb and finger
to release bezel.
Figure 1-1. 120 MB Hard Disk Drive – Air Filter
Trackball
The following procedure applies to the Trackball cleaning:
1. Turn the trackball assembly over on its back. Using a 5/64 Allen screwdriver, remove
the eight Allen-head screws.
2. Turn the assembly right-side up and remove the top cover.
3. Check the alignment of the ball to the rubber sleeve on the two shafts.
NOTE
If the shafts do not have sleeves, skip Step 4.
4. Remove the ball and center sleeves on both shafts. Apply one drop of super glue to
one end of each sleeve.
5. Clean both plastic wheels and photocells located at the end of each shaft with a
freon-based contact spray-cleaner. Make sure each (window) opening is cleared of
debris.
6. Place the ball in the proper location and test for smoothness of action.
7. Reinstall the cover. Turn the assembly over and install the screws.
8. Reconnect the trackball and check cursor and ball operation.
Wangtek TapePort Drive

Table 1-1 lists the recommended preventive maintenance for the tape drive. Additionally, clean
the drive if the tape software reports either a tape read, write, or tape verify error. If an error per-
sists, try a different data cartridge.
5
Table 1-1. TapePort Tape Drive Recommended Preventive Maintenance Schedule
Item Interval (or as required)

Head Cleaning 8 hours actual use or 30 days
Head Cleaning (new tape) 2 hours actual use or 7 days
Capstan Cleaning 8 hours actual use or 30 days
Head Cleaning
Access the tape head from the front of the drive cartridge access slot. Before you can clean the
head, you must move the head to the docked position by pushing in on the cartridge baseplate
using finger pressure only. Slide the plate inward until you hear a distinct click. Release the plate
and it slides outward, moving the head to the docked position.
Clean the head using only Freon TF and polyurethane swabs, commonly available with VCR head
cleaning kits. Wet the swab with the Freon TF solution, and wipe the head using an up and down
motion. Use a dry swab to clean any remaining residue from the head. After you clean the head
you must return the head to the undocked position by pressing inward on the cartridge baseplate
until you hear a distinct click. Release the plate and the head latches in the undocked position and
is ready for data cartridge insertion.
Drive Capstan Cleaning

Access the drive capstan from the front of the drive through the tape access slot. Use water and
polyurethane swabs.
! CAUTION
Do not clean the drive capstan with Freon TF or solvent. Permanent damage to the
capstan could result.
Perform the following steps to clean the capstan:

1. Wet a swab with water and wipe the capstan using an up and down motion. Use a dry
swab to dry any remaining residue from the capstan.
2. After the capstan is completely dry, install a data cartridge in the drive with the power
on, and perform a cartridge retention. This action rotates the capstan so you can clean
the other side.
3. Repeat the cleaning and drying procedure on the capstan.
6
2. Fault Analysis
This chapter contains diagnostic procedures which allow you to perform tests and check
procedures on the I/A Series components through the use of the I/A Series System Management
Service software. This service software enables you to monitor the health and performance of
the components, and locate the source of a fault to a replaceable control processor module,
Fieldbus Module, or peripheral device.
Through the System Management facility, you can monitor the health of the system and perform
diagnostic tests on all the system stations and associated peripheral devices.
The diagnostics performed are:
♦ Automatically invoked startup diagnostics.
♦ Operator-initiated and station-initiated Nodebus/Tokenbus test and Network Hard-
ware Diagnostics (system cable/receiver/transmitter tests).
♦ Operator-initiated off-line diagnostics for the 10, 20, 30 Series system stations and
also the control processors (CP10, CP30, and CP40). Off-line diagnostics are not per-
formed for the 50 Series system stations (AP50, AW51B, and so forth).
For reference information associated with detailed system management procedures that apply to
this document, refer to the System Management Displays Help screens.
Startup Diagnostics
Startup diagnostics are invoked automatically as a result of a power-on reset, an error, or an
off-line diagnostic command. The diagnostics exist in each station at all times and are of two basic
types:
♦ Reportable diagnostic – Tests a station function which, if faulty, does not prevent the
error from being reported over the network.
♦ Nonreportable diagnostic – Tests a station function which, if faulty, inhibits the sta-
tion from communicating over the network.
Not all stations are subject to the same startup diagnostic tests. The kernel diagnostics test all
hardware functions required to communicate over the Nodebus. Refer to the next section, “Star-
tup Diagnostic Tests” for the startup tests applying to system stations, Fieldbus Modules, and
peripherals.
Startup Diagnostic Tests

System station kernel diagnostics are those that test all hardware functions required to communi-
cate over the Nodebus. These functions include:
♦ RAM Memory
♦ Interrupt Controllers
♦ Watch Dog Timer
♦ State Sequencers
♦ Nodebus Coprocessor
7
B0193AD – Rev R 2. Fault Analysis
Fieldbus Module Startup diagnostics (see Table 2-1) check the components within the system
that are associated with the operation of the Fieldbus Modules. The diagnostics are ROM-
resident and execute on power-up or on command.
Table 2-1. FBM Startup Diagnostics
CHI Checksum Tests the EEPROM used for code memory.

CPU Verifies the 8044 internal RAM and processor function.
CGGA Tests the Clock Generator Gate array.
IOCGA Tests the I/O Controller Gate array.
Watch Dog Timer Tests the ability of the WDT to force a hardware reset.
Program RAM Tests the 8044 program RAM.
Peripheral Interface Startup diagnostics (see Table 2-2) check the components within the system
that are associated with operation of the peripheral interface. They are ROM-resident and execute
on power-up or reset.
Table 2-2. Peripheral Interface Startup Diagnostics
CHI Checksum Tests the EEPROM used for code memory.

CPU Verifies the 8044 internal RAM and processor function.
Watch Dog Timer Tests the ability of the WDT to force a hardware reset.
Program RAM Tests the 8044 program RAM.
Keyboard Tests the communication path to the keyboard for the keyboard interface.
Serial Port Tests the serial port via a loopback test for the mouse/touchscreen interface.
Operator Procedures for Fault Analysis Tasks

The following fault analysis tasks can be performed using the System Management Software:
♦ Run STATION FAULT TESTS (on-line and off-line diagnostics).
♦ Run STATION PERFORMANCE TESTS (event counters).
♦ Access FAULT LOCATION TABLES (station/peripheral equipment and status
information).
♦ Enable or inhibit alarms for equipment, LAN, Nodebus, PIO bus and stations, and
indicate such on displays.
The System Management Displays used to access and execute these tasks are as follows:
♦ System Monitor Domains Display
♦ System Monitor Display
♦ System Monitor Domain Display
♦ Inhibit Display
For information on accessing these displays and how they are used to execute the above-listed
fault analysis tasks, refer to the System Management Display Help screens. Also available in the
System Management Display Help screens are the System Health Color Coding and Network
8
2. Fault Analysis B0193AD – Rev R
Health Color Coding conventions, which indicate the status of various system and network func-
tions.
Fault Tests
System FAULT Tests consist of on-line diagnostics for Nodebus cable tests. These cable tests are
selectable through the NETWORK soft key located in the System Monitor Domain Display.
System FAULT Tests consist of On-line and Off-line diagnostics.
♦ On-line diagnostics consist of the Carrierband LAN LI (LAN Interface) cable tests
and Nodebus cable tests. These cable tests are selectable through the NETWORK soft key
located in all three System Monitor Domain Displays.
♦ Invoke Off-line diagnostics to check for, or verify the proper “independent” operation
of a station’s internal components. Off-line diagnostics are selectable through the
OFFLINE soft key located only in the System Monitor Domains Displays. Off-line
diagnostics are not supported on 50 Series stations or personal workstation PCs.
On-line Diagnostics
On-line diagnostics consist of Carrierband LAN LI (LAN Interface) Cable Tests and Nodebus
Cable Tests. These tests are either operator-initiated or automatically invoked to isolate faults and
to check the integrity of the communication path. Cable tests isolate problems with the Token
Bus, Drop Cables, and those associated with a station’s receiver or transmitter logic receiving and
transmitting a communication signal.
The Nodebus cable test is performed on the Nodebus local to the Network Fault Detection
(NFD) receiving the cable test request; and only to the stations on that LAN Interface (LI). For
example, if you suspect that one or more stations have communication problems and those sta-
tions are located on different Nodes, you need to invoke the cable test on each separate Nodebus
when you diagnose the problem.
A cable test initiator invokes layer-initiated testing. Cable test initiators include an LI (the default
initiator) or an AP20, AP50, or AP51 detecting a communication problem with the local Node-
bus or remote Nodebus stations. These cable tests are only performed on the local Nodebus by the
cable test initiator, and only on the stations associated with an initiator.
With both the operator-initiated and automatically invoked cable tests, the operator is notified of
the failure results. Fault isolation results are sent to a central logging device and printed as a
Priority 1 condition. A test “results” message also appears on the display monitor screen in a “mes-
sage line” above the top menu bar. You can clear the line by selecting the CLR MSG option.
All System Management Display Handlers (SMDH) in the network are notified of the failure,
including the one requesting the test. Success is only reported to the requestor.
Test Procedure
To test for on-line FAULTS, refer to the explanation of the System Health Display in the System
Management Help screens. On-line diagnostics can be accessed through any of the initial Net-
work Health Displays: System Monitor Domains, System Monitor, or System Monitor Domain.
(Refer to the System Management Help screens for a description of these displays.) The System
Monitor Domain Display is an example display for this procedure.
9
Carrierband LAN Display Access

Perform the following steps to access the Carrierband LAN Display:
1. Using the pointing device or touchscreen, select NETWORK. This produces the Carrier-
band LAN Display. (You can also access token bus cable tests from this screen.)
2. To access the Carrierband LAN Cable test, select the ONLINE DIAG soft key. This pro-
duces the On-line Diagnostic Display for the Carrierband LAN. Select the
Carrierband Cable Test function to test for the token bus, drop cables, station
transmitters, and receivers associated with the LAN. Refer to Figure 2-3 for an exam-
ple of the cable test selection display.
If a fault is indicated, refer to the network communications health color coding infor-
mation in the System Management Display Help screens to determine the precise
nature of the fault.
NOTE
This test can take up to two minutes to complete.
Refer to the System Management Displays Help screens for information on enabling/inhibiting
alarms.
Nodebus Display Access

An example Carrierband LAN Display is shown in Figure 2-1. The Nodebus Display, Figure 2-2,
is accessed via the NEXT LEVEL soft key on the Carrierband LAN Display.
Select the ONLINE DIAG soft key on the Nodebus Display screen to invoke the Nodebus cable tests
as well as other associated operations. The current Nodebus Master is used as the test initiator.
1. Select the graphic of the first of two stations to be tested.
2. Next, using the pointing device or touchscreen, select the ONLINE DIAG soft key. This
produces the On-line Diagnostic Display for the LI, Figure 2-3. Note the four Node-
bus Cable test options.
3. Using the pointing device or touchscreen again, select the RUN NODEBUS CABLE TEST
to complete the function. This produces an overlay on the screen containing a list of
remaining stations on the Nodebus.
4. Select a station to be the second station to be tested. This test takes approximately
ten seconds to execute.
If a fault is indicated, refer to the network communications health color coding infor-
mation in the System Management Display Help screens to determine the precise
nature of the fault.
To access the Nodebus On-line Diagnostics Display (see Figure 2-4) select the ONLINE
DIAG soft key.
Refer to the System Management Displays Help screens for information on enabling/inhibiting
alarms.
10
Figure 2-1. Carrierband LAN Display
Figure 2-2. Nodebus Display
11
Figure 2-3. Carrierband LAN On-line Diagnostics Display
Figure 2-4. Nodebus On-line Diagnostics Display
12
PIO Bus Display Access

The PIO Bus Display, Figure 2-5, is selectable via the NEXT LEVEL soft key on the Nodebus Dis-
play. PIO Bus communication is monitored periodically on Bus A and Bus B. Status information
concerning the PIO bus diagnostics can be viewed on the Equipment Information screen and on
the Station Display via the EQUIP INFO soft key.
Refer to the System Management Displays Help screens for details concerning system messages
associated with On-line Diagnostic tests. This document addresses the “message line” (screen dis-
played or printed), any occurring symptoms, and corrective action required to restore communi-
cation success.
Refer to the System Management Displays Help screens for the procedures related to, and a
description of printer Priority 1 and 2 conditions, and for inhibiting and enabling alarms.
Figure 2-5. PIO Bus Display
Nodebus Cable Test Loopback Message Reporting

The Nodebus cable test isolates faults associated with two physical cables (Cable A and cable B).
Cable testing is predicated on the idea that messages can still be sent out over at least one of the
Nodebus cables, A or B. Each cable can be either request or response (AA, BB, AB, BA) as deter-
mined by the communication subsystem. System Monitor can select one cable (A or B) as the pri-
mary communications path, and the other cable for the secondary communications path.
Path AB is cable-set by default with both operator-initiated and layer-initiated conditions. Refer
to the System Management Displays Help screens for details concerning messages associated with
On-line Diagnostics and Nodebus Cable Test loopback message reporting. When testing a cable
on the Nodebus, an attempt is made to distinguish between cable failures, station receiver, or sta-
tion transmitter failures. NFD sends “Loopback messages” indicating which cable returns a mes-
sage. For example, loopback request messages are sent to a station to make the determination in
the following sequence:
13
1. A loopback request is sent on Cable A requesting a response on Cable A.

(AA request).
2. A loopback request is sent on Cable B requesting a response on Cable B. (BB request).
3. A loopback request is sent on Cable A requesting a response on Cable B. (AB request).
4. A loopback request is sent on Cable B requesting a response on Cable A. (BA request).
Considering these reporting conditions:
1. If there was a “no response” to both the AA and BB request, the station is not commu-
nicating on either cable and it exits from the test without requesting further loopbacks
from AB or BA. NFD indicates “not responding” test results.
2. If responses were received to both the AA and BB requests, then both cables would
respond “good,” and no further testing is done.
3. If only “one” condition, “AA” or “BB” response was received, then the AB and BA
request are sent. The diagnosis is then made based on the four loopbacks sent.
As a reference to possible communication states occurring during the transmission of a signal,
refer to the following screens exhibiting a condition truth table. The conclusions shown in this
table are indicative of the messages described in the System Management Displays Help screens.
The truth table conditions are listed in Table 2-3.
1 Indicates a condition (* timed out) where the cables transmission, and/or the com-
municating station or System Monitor Transmitter/Receiver communication paths
are NOT RESPONDING.
0 Indicates a condition where all communication paths are RESPONDING.
Table 2-3. Cable Faults Truth Table
Message Paths Conclusions

AA BB AB BA
0 0 - - Both cables and station are good.
1 1 - - Station associated with cable test has receiver or transmitter
problems, and/or both cables are bad.
1 0 1 1 Cable A is suspect.
0 1 1 1 Cable B is suspect.
0 1 0 1 Station associated with the cable test has bad Receiver B.
0 1 0 1 NFD has bad Transmitter B.
0 1 1 0 Station associated with the cable test has bad Transmitter B.
0 1 1 0 NFD has bad Receiver B.
1 0 1 0 Station associated with the cable test has bad Receiver A.
1 0 1 0 NFD has bad Transmitter A.
1 0 0 1 Station associated with the cable test has bad Transmitter A.
1 0 0 1 NFD has bad Receiver A.
14
NOTE
Local traffic invokes a cable test when a problem arises. The cable state switches
every 24 hours. That is, the default path changes from AB to BA to AB, and so on,
every 15 minutes to assure complete fault detection. The System Monitor runs tests
only with stations on its local Nodebus and in its domain.
Off-line Diagnostics
Off-line diagnostics are used to check for, or verify the proper “independent” operation of a sta-
tion’s internal components. These tests do not verify any external reason for failure, thus they can
be individually bench tested without regard to the station’s subsystem configuration.
! CAUTION
Selecting the Offline option automatically takes the station off-line. If required, an
alternate means of control should be provided. Only authorized personnel should
consider such action.
Proceed as follows:
1. Using the pointing device or touchscreen, select OFFLINE DIAG to display the off-line
diagnostic tests related to the system station highlighted on the screen.
Figure 2-6 and Figure 2-7 show typical off-line diagnostic displays. Other following
figures show the tests that apply to the various system station types. An explanation of
the station diagnostics is provided in “Station Diagnostic Tests” on page 18.
Select a display (see Figure 2-7) as an example figure for the following steps.
2. Using the pointing device or touchscreen, select one or a set of desired diagnostic tests
to be performed.
3. Select the EXECUTE option.
EXEC ONCE – executes the selected set of tests.
EXEC LOOP – executes continuously.
The tests halt if one of two events occurs:
♦ Tests fail.
♦ If you select the HALT option shown in Figure 2-13, Off-line Diagnostic
Results Display.
EXEC ALL – executes all diagnostics for the station once.
4. Select the RECOVERY option (RESTART or FAIL), or exit the screen to leave the module
in Off-line Diagnostic Dispatcher (OLDD).
RESTART – Restarts the station.
FAIL – Fails the station.
PASS/FAIL results for each station appear on the screen as they arrive from the station
and are displayed immediately. A running total of passed and failed tests is displayed
at the bottom of the screen (see Figure 2-13).
15
NOTE
Should a station fail any one of these tests, it is considered faulty and should be
replaced.
The test status results are:

♦ PASS
♦ FAIL – EXECUTE (executed and failed)
♦ FAIL – DOWNLOAD (never executed)
You can choose to halt the loop to either RESTART or FAIL a station. The HALT button shown in
Figure 2-13 is always displayed, but you can select it only when the EXEC LOOP option is selected.
NOTE
As the tests sequence, the color of the test being run changes from black to green;
green indicates the parameter is under test.
If three of the tests result in “no response” action, then the message line at the top of the screen
indicates station not responding and the test loop stops.
You must return to the Off-line Diagnostic Display and select EXEC LOOP to restart the loop.
If you choose to RESTART or FAIL a station (executed at any Off-line Diagnostic Display), the
screen redisplays the Faults Option Display.
To RESTART a module that has been “failed,” power must be removed and reapplied, thus invoking
startup diagnostics.
16
Figure 2-6. Off-line Diagnostics Display, Typical
Figure 2-7. Off-line Diagnostics, Communication Processor 15, INI(s), and Gateways
17
Station Diagnostic Tests

The following sections depict the various diagnostic tests performed on I/A Series system stations
by the system software. These tests confirm the operation, communication and control parame-
ters, or non-operation of the self-contained station components. Note there are a number of sta-
tions that have identical test parameters. These parameters are indicated in the respective text
sections and associated figures. Figure 2-6 shows a typical Off-line Diagnostic Display.
NOTE
Should a station fail any one of these tests, it is considered to be faulty and should
be replaced. To assure that the failure is a result of self-contained components,
reboot action is advised. This essentially eliminates the possibility of intermittent
error.
Communication Processor 10 and 760/761 Gateway

The following diagnostic tests (see Table 2-4), are performed on the Communication Processor
10 and the 760/761 Gateway. Refer to Figure 2-7.
Table 2-4. Communication Processor 10 and 760/761 Gateway Diagnostics
DMA WRITE Tests the hardware interface to the Direct Memory Access (DMA)
Controller.
SCC RD/WRT Verifies hardware registers located inside both Serial Communications
Controllers (SCC).
M/P/M TEST Performs a memory to SCC synchronous loopback to memory DMA
transfer and verifies the results.
ASYNC LPBK Performs an internal loopback test on both channels of each SCC.
LETTERBUG Tests the module identifier address character and compares the value
against configuration table for validity and position.
Communication Processor 15/30, INIs, and Gateways

The following diagnostic tests (see Table 2-5), are performed on the following stations:
♦ Communication (Gateway) Processor 15
♦ Allen-Bradley Data Highway Gateway
♦ Allen-Bradley Data Highway Gateway Redundant
♦ Integrator 30 for ABDH
♦ Integrator 30 for ABDH Redundant
♦ Modicon Gateway
♦ Integrator 30 for Modicon
♦ Device Integrator
♦ Device Integrator 30
♦ Instrument Gateway
♦ SPECTRUM Master Gateway – Redundant (SIP)
18
♦ SPECTRUM Master Gateway – Non-Redundant (SIP-R)

♦ Information Network Interface 15
♦ Instrument Gateway (Version 2)
Refer to Figure 2-7, which shows the relevant System Manager Display.
Table 2-5. Communication Processor 15/30, INIs, and Gateways Diagnostics
DMA WRITE Tests the hardware interface to the Direct Memory Access (DMA)
Controller.
SCC RD/WRT Verifies hardware registers located inside both Serial Communications
Controllers (SCC).
M/P/M TEST Performs a memory to SCC synchronous loopback to memory DMA
transfer and verifies the results.
ASYNC LPBK Performs an internal loopback test on both channels of each SCC.
LETTERBUG Tests the module identifier address character and compares the value
against configuration table for validity and position.
8087 TEST Verifies mathematical functions of 8087.
Control Processor 10, 30, and 40

The following screens (see Table 2-6), describe the diagnostic tests performed on the Control Pro-
cessor 10, 30, and 40. Refer to Figure 2-8 shown by the System Manager software.
Table 2-6. Control Processor Diagnostics

NODEBS COM Nodebus compare logic test, through use of built-in test functions, verifies
Fault-Tolerant Compare Logic. (Omitted for the CP30 and CP40.)
LETTERBUG Tests the module identifier address character and compares the values
against configuration tables for validity and position.
FBM PORT I/O Processor test verifies the Shared RAM Interface to the Fieldbus
subassembly; then initiates the Fieldbus diagnostics which run via the
8044 I/O Processor and verifies the results.
19
Figure 2-8. Off-line Diagnostics, Control Processors 10, 30, and 40
Application Processor 20
The following diagnostic tests (see Table 2-7), are performed on the Application Processor 20.
Refer to Figure 2-9.
Table 2-7. AP20 Diagnostics
SCSI TESTS I/O Processor Test verifies the Shared RAM interface to the Small Computer
System Interface (SCSI) subassembly; then initiates the SCSI Diagnostics
which run via the 8051 I/O Processor, and verifies the results via the following
tests:
♦ CPU – Verifies 8051 internal RAM and Processor function.
♦ Program RAM – Tests the 8051 program RAM.
♦ Shared RAM – Verifies the Shared RAM from the 8051 side.
MEM DMA Performs memory to memory DMA transfer and verifies results.
ADMA DMA Verifies all addressable hardware registers located inside the ADMA DMA
Controller.
LETTERBUG Tests the module identifier address character and compares the value against
configuration table for validity and position.
CLNDR CLK Tests the ability to write a date and time to the calendar clock IC and verifies
that the clock runs.
20
Figure 2-9. Off-line Diagnostics, Application Processor 20
Workstation Processor 30
The following diagnostic tests (see Table 2-8), are performed on the Workstation Processor 30.
Table 2-8. WP30 Diagnostics
GSP_GE Tests the internal 386 graphic engine and memory (video RAM and
dynamic RAM).
8087 TEST Verifies the mathematical functions of the 8087.
GCPIO Verifies the shared RAM interface to the Workstation Processor
I/O subassembly after a cold start diagnostic test, then initiates the
WP I/O diagnostics and verifies the results.
GSP_HOST Tests the letterbug of the host and compares the value against a table for
validity and position.
SPECTRUM Slave Gateway

The following diagnostic tests (see Table 2-9), are performed on the SPECTRUM Slave Gateway.
Refer to Figure 2-10.
Table 2-9. SPECTRUM Slave Gateway Diagnostics
21
Table 2-9. SPECTRUM Slave Gateway Diagnostics (Continued)
NODEBS COM Nodebus compare logic test through use of built-in test functions,
verifies Fault-Tolerant Compare Logic.
CLNDR CLK Tests the ability to write a date and time to the calendar clock IC and
verifies that the clock runs.
PORT TEST Tests the Port Command Registers and the SSG Interrupt Controller.
DMA TEST Tests the DMA request logic for the Main Data Flow Controller and
the ability of the ADMA to perform I/O to memory transfers.
ADMA DMA Verifies all addressable hardware registers located inside the ADMA
DMA Controller.
SSG MAIN Performs a loopback test on the Main Data Flow Controllers.
SSG SEC Performs a loopback test on the Secondary Data Flow Controllers.
Figure 2-10. Off-line Diagnostics, SPECTRUM Slave Gateway
Tank Processor 10
The following diagnostic tests (see Table 2-10), are performed on the Tank Processor 10. Refer to
Figure 2-11 shown by the System Manager software.
Table 2-10. Tank Processor 10 Diagnostics
8087 TEST Test verifies mathematical functions of 8087.
22
Table 2-10. Tank Processor 10 Diagnostics
NODEBS COM Nodebus compare logic test, through use of built-in test functions,
verifies Fault-Tolerant Compare Logic.
LETTERBUG Letterbug tests the module identifier address character and compares
the values against physical tables for validity and position.
I/O PORT I/O Processor test verifies the Shared RAM Interface to the I/O
subassembly; then initiates the I/O diagnostics which run via the 8044
I/O Processor, and verifies the results via the following tests:
♦ CPU – Verifies 8044 Internal RAM and Processor Function.
♦ Program RAM – Tests the 8044 Program RAM.
♦ Shared RAM – Verifies the Shared RAM from the 8044 side.
♦ Timer Test – Functionally tests the 82C54 Programmable Timer IC.
♦ Peripheral Interface Test – Verifies the interface to the 82C55
Peripheral Interface IC.
Figure 2-11. Off-line Diagnostics, TP10
Carrierband LAN Interface

Off-line diagnostic testing performed on Carrierband LAN Interface (CLI) is limited to the Let-
terbug (Station ID). Refer to Table 2-11 and Figure 2-12.
Table 2-11. Carrierband LAN Interface Letterbug Diagnostic
23
Figure 2-12. Off-line Diagnostics, Carrierband LAN Interface
Figure 2-13. Off-line Diagnostic Results Display (Typical)
24
INTERSPEC Integrator
The following diagnostic tests are available for the INTERSPEC Integrator (IS30).
Table 2-12. Diagnostic Test for INTERSPEC Integrator

I/O PROCESS Tests the integrity of the 186 (I/O) subsystem of the station.
LETTERBUG Tests the module identifier character and compares the values
Station Performance Tests

The communication performance of the station itself, the station within the network, and any
peripheral(s) attached to the station can be monitored and analyzed through the use of various
counters. These are shown in the System Management Counter and Peripheral Counter
options, discussed later in this section. These counters are cumulative counters representing com-
munication events that occur on the network. The counters are accessed from the System Man-
agement Counter options and the Peripheral Counter options. For example, the events can be
the number of successful transmissions, number of retries, or number of messages dropped.
To test a station for communication PERFORMANCE, proceed as follows:
1. Using the pointing device or touchscreen, select the station to check for
PERFORMANCE.
2. Once the station selection is made, select the PERF task option at the bottom of the
screen. The result produces the Performance Options Display shown in Figure 2-14.
In the Performance Options screen, you can select either of two options, the SYSTEM
MANAGEMENT COUNTERS explained in Steps 3 through 5, or PERIPHERAL COUNTERS
explained in Steps 6 and 7. Within these two categories, you can read, set, and reset a
station or peripheral EVENT COUNTERS.
3. To proceed, select the SYSTEM MANAGEMENT COUNTERS option. This displays a list of
station communication performance counter categories shown in Figure 2-15, System
Management Counter Categories.
The first six counter categories represent the different layers of the network communi-
cation software protocol. These sets of counters track communication events – for
example, transmission errors, starts, retries, and stops.
25
Figure 2-14. Performance Options Display
Figure 2-15. System Management Counter Categories Display
26
The Software Loading Parameters category gives static counter information related to
uploading and downloading of station software.
Each category has its own set of counters that relate to the health and performance of
the station. These are listed and explained in the section “Explanation of System
Event Counters” on page 29.
NOTE
1. An explanation of event counters for each category is also available using the sys-
tem On-line Help function.
2. The Physical Layer, LLC Layer, Station Manager, and COMM buffer categories
have NO COUNTERS available.
4. From the System Management Counter Categories Display, use the pointing device or
touchscreen and select the counter category desired. This produces a Station Manage-
ment Counters Display shown in Figure 2-16. This figure is a typical display example
showing the first page of the MAC sublayer counters for Application Processor 20.
5. Using the pointing device or touchscreen again, select the desired action, READ ALL,
RESET ONE, or RESET ALL counters, shown at the base of the display.
READ ALL rereads the counter information and displays the most current values for the
chosen communication layer.
When a specific counter is selected from the list, RESET ONE becomes selectable.
Selecting RESET ONE (when selectable) or RESET ALL sets the selected counter or all
displayed counters to zero and automatically rereads the latest counter value(s). You
can then continue to periodically select READ ALL to see the change in counter value(s)
within the time frame between each selection of READ ALL.
6. Return to the Performance Display using the action icons at the far left of the display.
Select the PERIPHERAL COUNTERS option. This produces the Peripheral Names and
Types Display on the screen, Figure 2-17. From here you can access the events
counters associated with the station peripheral (that is, FBMs, gateways, bulk storage,
and printers).
7. Using the pointing device or touchscreen, select the station peripheral desired.
An FBM selection produces the Peripheral Counters Display shown in Figure 2-18.
Selecting other peripherals produces different counters.
8. Using the pointing device or touchscreen again, select the desired action, READ ALL,
RESET ONE, or RESET ALL counters, as shown at the base of the display. Table 2-18
explains the various peripheral counters and their threshold values.
For a more detailed explanation and list of counter display functions, refer to the Sys-
tem Management Displays Help screens.
27
Figure 2-16. MAC Sublayer Counters Display
Figure 2-17. Peripheral Names and Types Display (Control Processor)
28
Figure 2-18. Peripheral Counters (FBM)
Explanation of System Event Counters

Field service personnel may use the System Event Counters to deduce possible equipment failures
by viewing the counters through the System Management Display (SMDH) on-site. The PRFI
column represents “Possible Reason For Increment,” and is provided with each counter to deter-
mine possible corrective action. Refer to the System Management Displays Help screens for
counter definitions and associated acronyms shown in the following tables.
29
Table 2-13. MAC Sublayer Counters
Threshold Possible Reason

Counter Name Explanation Of Counter Value* For Increment
COLLISIONS** Number of collisions <5% of Frames Bad cable or bad receiver if
experienced by the con- transmitted very large values are observed
troller chip during trans- over short periods of time.
mission attempts. Low values (less than thresh-
old) are norm for 30 second
intervals. Possible heavy net-
work traffic.
TRANSMITS Number of times the <5% of Frames Possible bad cable, bad
DEFERRED** controller chip had to transmitted receiver or very heavy loaded
defer traffic during the network for large value over
first transmission short periods. Occasionally
attempt. DEFER may appear, and is
acceptable if less than thresh-
olds levels over 30 seconds.
DMA UNDER- Number of times the sta- 4 (LI, PW) all Signifies a hardware error on
RUNS** tion ran out of internal others = 0 local station, notify service.
bus bandwidth.
EXCESS COLLI- Number of unsuccessful 0 Bad cable or bad receiver.
SIONS** transmissions because Possible very heavy network
the number of collisions traffic.
exceeded the maximum
allowed per packet.
CRC ERRORS** Number of received 0.1% of frames Bad cable or bad local receiver
properly aligned frame received (com- or remote transmitter if
with a CRC error. bined values of threshold is exceeded in 30
CRC ERRORS seconds.
ALIGN ERR** Number of misaligned and ALIGN Bad local receiver or ext trans-
received frames with ERR counters) mitter.
CRC error.
DMA OVRRUN** Number of frames lost 4 (LI, PW) all Signifies hardware error on
because memory bus was others = 0 local station notify service
not available to control- personnel.
ler chip.
NO RECEIVE Number of received 0.1% of frames Possible station overload or
RESOURCES** frames lost due to mem- received incoming traffic in process.
ory resource problem in
station.
802.3 MAC Number of times the 2*** Bad cable, bad hardware, hot
RESETS 82586 MAC was initial- remarries.
ized due to transmission
errors and hot remarries.
30
Table 2-13. MAC Sublayer Counters (Continued)

FRAMES TRANS- Number of frames suc- 180,000 Each message transmitted on
MITTED cessfully transmitted. network increments this
counter by 1.
FRAMES Number of frames suc- 180,000 Each received message incre-
RECEIVED cessfully received. ments this counter by 1.
802.4 MAC Number of times the 2 (LI) all others Bad cable, bad hardware, hot
RESETS 68824 MAC was initial- =0 remarries.
ized due to transmission
errors and hot remarries.
This counter relates to LI
station only.
* The values of these counters are guidelines and can be affected by system dynamics. Exceeding one
of these values is not a definite indication of a problem or system error.
* *The values of these counters are not reported for a fault-tolerant station (excluding the LI station)
running married: DMA Underruns, Excess Collisions, CRC Errors, Align Errors, No Receive
Resources, DMA Overrun, Collisions, and Transmits Deferred.
***For Fault-Tolerant configuration, this value will increment once a week due to a forced hot
remarry. This hot remarry is scheduled by the Fault-tolerant executive.
Table 2-14. Transport Layer Counters
Explanation Of Threshold Possible Reason

Counter Name Counter Value* For Increment
CHECKSUM Number of TPDUs 0 Possible hardware
ERRORS received with check error on the local or
sum errors. descending station.
DISCONNECTS Number of established No threshold Acceptable applica-
REQUESTED connections broken tion request.
due to a local or Transport Layer not
remote application needed.
request.
CURRENT # CON- Number of connec- ♦ Max 17 for V2.2 Incremented for each
NECTIONS tions currently estab- CPs, GWs connect established,
lished. This counter is ♦ Max 51 for V3.0 decremented for each
unsettable. CP30, CP40 connection broken.
Refer to System Sizing ♦ Max 48 for AP20s
Guidelines for infor- (12 OM)
mation. ♦ Max 35 for V3.0
WPs (32 OM)
31
Table 2-14. Transport Layer Counters (Continued)

CONNECT DATA Number of success- 180,000 Each connection data
TPDUS TRANS fully transmitted con- packet transmitted
nection-oriented (non-ack) increments
TPDUs. by 1.
CONNECT DATA Number of success- 180,000 Each connection data
TPDUS RECVD fully received oriented packet received incre-
TPDUs. ments counter by 1.
CONNECTS Number of connec- 0 System overload
DENIED- tions request denied condition.
RESOURCES due to lack of Trans-
port Layer (TL) Local
resources.
CONNECTS Number of connec- 10 Application not ready
DENIED-APP tion request denied by to get connections.
a local application.
CONNECTS Number of connec- 0 The local TL detects
DENIED-TL tion request denied by one of the following
the Transport Layer errors; peer connec-
(TL). tion not valid; destina-
tion station not
available.
DISCONNECTS Number of established 0 This is incremented
DUE TO ERRORS connections that broke only if an established
due to error. connection senses one
of the following con-
ditions: retransmits are
exceeded and TL did
not acknowledge a
TPDU; no TPDUs
were received from a
peer TL in a sufficient
time period; the peer
TL broke connection
due to one of the pre-
vious conditions.
RETRANS DATA Number of retransmit- 0.2% of Data TPDUS Bad cable, receiver,
TPDUS ON A ted TPDUs on transmitted transmitter. Overload
Cable A (Transport on path. Destination
Protocol Data Units). invalid or never
reached.
32
Table 2-14. Transport Layer Counters (Continued)

RETRANS DATA Number of retransmit- 0.2% of Data TPDUS Same as Cable A.
TPDUS ON B ted TPDUs on transmitted
Cable B (Transport
Protocol Data Units).
Table 2-15. Application Layer Counters

CNLS-UNACK Number of connectionless <10,800** Each received connec-
RECEIVED unacknowledged data tionless unacknowl-
received by provided Appli- edged packet increments
cation Layer. this counter by one.
CNLS-UNACK Number of connectionless <10,800** Incremented by 1 when
TRANSMITTED unacknowledged data pack- sent.
ets transmitted by Appl.
Layer.
NO TUCB AVAIL- Number of connectionless 5 A lack of available
ABLE data packets not sent due to a TUCBs indicates the
lack of available TUCBs control structures a
(Transmit Unit Control located to process current
Blocks). outgoing message to the
traffic is insufficient.
NO RUCBS AVAIL- Number of connectionless 5 A lack of available
ABLE data packets rejected due to a RUCBS indicates an
lack of available TUCBs insufficient number of
(Receive Unit Control control structure allo-
Blocks). cated to process current
incoming traffic and
reconfiguration may be
necessary.
CNLS-ACK TRANS- Number of connectionless 180,000 Incremented by 1 when
MITTED acknowledged data packets sent.
transmitted by Appl. Layer.
RETRANS Number of retransmitted 0.2% of Cable problems (one or
CL-ACK ON A acknowledged data packets CNLS-ACK more cables, or transitory
on Cable A. transmitted problems may be respon-
sible for ack never arriv-
ing, resulting in
retransmission.
33
Table 2-15. Application Layer Counters (Continued)

CNLS-ACK Number of connectionless 180,000 Incremented by 1 when
RECEIVED acknowledged data packets received.
received by Application
Layer.
RETRANS Number of retransmitted 0.2% of Cable problems (one
CL-ACK ON B connectionless acknowl- CNLS-ACK cable, two cables, or tran-
edged data packets on transmitted sitory problems affecting
Cable B. cables) may be responsi-
ble for acknowledgment
never arriving resulting
in retransmission.
LLC FRAMES Number of LLC frames For AP = no Incremented by 1 each
RECEIVED received direct from LLC threshold; all time received.
Layer bypassing Transport others = 10
and Network Layers.
LLC FRAMES Number of LLC frames For AP = no Incremented by 1 each
TRANSMITTED transmitted directly to the threshold; time sent.
LLC Layer bypassing Trans- all others = 10
port and Network Layers.
LLC FRAMES DIS- Number of LLC frames 0 Memory overload: lack
CARDED received direct from LLC of space available.
Layer but discarded due to
lack of memory for the
Application Layer to copy
the message and pass it on.
** This value is a system-wide, and not a station-based value.
34
Table 2-16. Network Layer Counters, LI Only
Threshold Possible Reason for

Counter Name Explanation of Counter Value* Increment
DESTINATION Number of messages 1 Destination LI not avail-
UNKNOWN dropped because the desti- able. Physical address of
nation node ID was destination node not
unknown. known.
PDUS RELAYED Number of PDU (Proto- 3,300 Packets routed or
col Data Unit) messages dropped exceeded loading
which pass through the LI. guideline increments
counter by 1.
All of the following loading parameters are statically configured and are not manually adjustable.
They relate to loading of station images and are available for performance monitoring and tuning
purposes.
Table 2-17. Station Loading Counters
Counter Name Explanation Of Counter Static Value

RLS_RETRY_COUNT Number of times the ROM Load Serve (RLS) 250 retries
requests completion status from a Loadable
Device (LD).
MAX_BLOCK_SIZE Maximum data block size in octets that a station 1400 octets
can accept for loading.
MIN_BLOCK_SIZE Minimum data block size in octets that a station xxxx octets
can accept for loading.
MAX_BLOCK_DELAY Maximum time in milliseconds that a LD can 32760 milliseconds
tolerate between transmission of individual data
blocks.
BLOCKS_PER_GRP Number of blocks in logical group (note: files are 256 blocks/ logical
segmented into groups for the purposes of load- group at 1400 octets
ing images). per block
LD_RETRY_COUNT1 Number of times load request is sent before load 3 retries
is considered failed.
LD_TIMER_T1 Time, in milliseconds, that LD waits for a load 3000 milliseconds
response before issuing another Load Request.
35
Table 2-18. Peripheral Counters
Threshold
Counter Name Explanation of Counter Value Possible Reason for Increment
RECVRED ER Number of times a device 1 Possible temporary failure on
encountered an error but was device. The operation succeeded
able to recover. Number of on retries.
errors.
MEDIUM ER Number of times medium 1 Retries failed writing or reading
error occurred on medium device.
hard disk, floppy, tape, and so
forth.
HARDWARE ER Number of errors occurred 1 Hardware error noticed at the
due to hardware failure (con- device, notify field service
troller, and so forth). personnel.
PARITY ER Number of errors occurred on 1 Can be bad SCSI bus or station/
SCSI bus. device SCSI bus interface if
threshold is reached.
MSGS DROP Number of alarm messages 30 Exceeding the threshold in a
that could not be printed 30 second interval can mean the
because output devices failed. primary and backup print devices
are non-operational. Incorrectly
configured primary and backup
devices can be the cause also.
Station Status Displays

The Station Status Displays produce a graphic description of the system station and attached
peripheral devices. It allows retrieval of STATUS INFORMATION concerning the station or
peripherals and devices attached to peripherals. Additionally, it allows qualified service personnel
or workstation operators to execute EQUIPMENT CHANGES associated with either a station
or peripheral device.
This subsection describes the various change categories and status information displays associated
with a station and peripherals. The subsection “Fault Location Tables” on page 38 addresses the
Fault Location Tables (FLTs) that lists the symptom and action possibilities associated with each
change category. The FLTs also lists the action required to an “unacceptable” or “unanswered”
response from a specific line in the Information Displays. For detailed information concerning the
Station Status Displays, refer to the System Management Displays Help screens.
To check a STATION for its existing status, proceed as follows:
1. Using the pointing device or touchscreen, select the station to view.
2. Once a station selection is made, select the CONFIG option at the base of the System
Monitor Domain Display. The result produces the Station and Peripheral Graphic
Display, Figure 2-19. Shown here is a graphic display of the station chosen to view
along with peripheral devices assigned to it.
36
At this point you can select either of two options, the EQUIP CHG explained in Steps 3
through 5, or EQUIP INFO explained in Step 6 (Figure 2-19). A third option dealing
with Equipment Information is the NEXT LEVEL. The NEXT LEVEL button becomes
pickable only if the peripheral is the Fieldbus Module (FBM18, FBM39, FBM43,
FBM44, or FBM46) or the I/A Series Mass Flowmeter (formerly Coriolis Transmit-
ter). The FBM is attached to the Intelligent Field Devices. The Mass Flowmeter is a
field device (containing a transmitter) which connects to CORINT module.
EQUIP CHG becomes selectable only if the workstation has been designated to perform
equipment change options and acknowledge the health state of the selected device.
Refer to the System Configurator (B0193JH) document for a description of the System
Monitor WP lists.
Figure 2-19. Station Configuration Display (with FBM44 selected)
3. Using the pointing device or touchscreen, choose a graphic block (that is, a station or
peripheral), and execute. The graphic block background changes color, and the but-
tons, EQUIP CHG, EQUIP INFO, and NEXT LEVEL (depending on peripheral type),
become pickable (white text), as shown in Figure 2-19.
4. Select the EQUIP CHG option. This produces the Equipment Change Displays shown
in Figure 2-20, “Station Change Options Display” on page 39, and Figure 2-21,
“Peripheral Change Options Display” on page 41. The associated Fault Location
Tables (FLTs) are located in the “Station Equipment Changes – Fault Location Table”
on page 39 and “Peripheral Equipment Changes – Fault Location Table” on page 41.
5. Using the pointing device or touchscreen, select the category requiring a change in
status. If it is an enable or disable change to be made, the active category is pickable
37
(white text). The “enable” and “disable” categories act as toggle switches within the
software.
All other categories chosen indicate their results via a message line at the top of the
screen. The results are either “Action Successful” or “Action Failure.”
! CAUTION
The subsection “Fault Location Tables” on page 38 addresses the categories of
changes, fault symptoms, and corrective action possibilities that apply to both the
system stations and peripheral devices. Only qualified service personnel should be
allowed to investigate “to be applied” corrective possibilities.
6. To review the Equipment Information Display associated with the station or periph-
eral chosen, return to the Station Display, Figure 2-19 using the action arrows at the
far left of the screen, or select the EQUIP INFO option. This selection produces a status
overlay listing network information on the station or peripheral chosen, as shown in
Figure 2-22 and Figure 2-23 through Figure 2-30. The associated Fault Location
Tables (FLTs) appear on subsequent pages.
7. If the peripheral chosen to view for information purposes contains associated ported
devices (FBM18, FBM43, FBM44, or FBM45), or is the I/A Series Mass Flowmeter,
the third option, NEXT LEVEL button on the Station Display becomes pickable (white
background). Figure 2-23 shows the information status displays associated with the
Intelligent Field Device. The associated Fault Location Table (FLT) is located in
“Intelligent Field Device Information – Fault Location Table” on page 48.
Fault Location Tables

The Fault Location Tables (FLTs) described in the following subsections apply to the station and
peripheral System Management Displays. These displays, listed below, are controlled by the
I/A Series System Management Display Handler (SMDH) and System Monitor software. They
contain the various station and peripheral equipment change options and information overlays:
♦ Station Equipment Changes
♦ Peripheral Equipment Changes
♦ Station Information Displays
♦ Peripheral Information Displays
♦ Intelligent Field Devices Information Displays
For additional details concerning the status and action information listed in the FLTs, refer to
Foxboro service personnel.
The Station and Peripheral Equipment Change options shown in the Fault Location Tables are
the same for each type of station or peripheral. However, the selectable options differ depending
on the station or peripheral type.
The displays offering information shown in the FLTs on stations are the same for each type. How-
ever, the displays offering information shown in the FLTs on peripherals vary depending upon the
peripheral type.
38
Station Equipment Changes – Fault Location Table

This Fault Location Table (see Figure 2-20) addresses the OPERATOR ACTION fields on the Station
Equipment Change Display and contain recommended check procedures. The table describes the
fields on the Equipment Information screen and may not be the total solution to an existing sta-
tion problem. Caution should be applied when addressing these parameters and action should be
performed only by qualified personnel. If further assistance is needed, contact the appropriate
Foxboro service personnel.
Refer to the System Management Displays Help screens for detailed equipment change parame-
ters associated with the various stations.
Figure 2-20. Station Change Options Display
Table 2-19. Station Equipment Changes – Fault Location
Operator Action Status Recommended Check Procedures

CHECKPOINT Checkpoint a) Check for other Work station Processors in the CIO
COMMAND Failure or SMDH configurator accessing Control Processor
(CP).
b) Verify CPs host Application Processor.
c) Verify the state and condition of the CP.
ENABLE STATION Not responding Station or device not on-line, or not failing.
ALARMING
INHIBIT STATION Not responding Verify device or station processor.
ALARMING
39
Table 2-19. Station Equipment Changes – Fault Location (Continued)

REBOOT STATION Image not a) Verify station’s Application Processor.
reloaded b) Verify reinstall procedure (if done).
c) Verify station’s system monitor’s host AP.
d) Download must be enabled.
e) Make sure no other WPs are running the CIO
configurator for the CP.
f ) Make sure no other WPs are running the Equipment
Change options for the PWWP via the SMDH.
ENABLE ALL Not responding Verify station’s system monitor’s host Application
REPORTS Processor.
DISABLE ALL Not responding Verify station’s system monitor’s host Application
REPORTS Processor.
EEPROM UPDATE Operation a) Check state and condition of the station. Cannot be
Incomplete in Off-line Diagnostic Dispatcher (OLDD).
b) Station must be on-line and NOT failed.
c) Verify station’s Application Processor.
d) Verify reinstall procedure (if done).
e) Verify station’s system monitor’s host AP.
f ) Download must be enabled.
g) Make sure no other WPs are running the CIO con-
figurator for the CP.
h) Make sure no other WPs are running the Equipment
Change options for the WP via the SMDH.
ENABLE UPLOAD Action Not a) Verify station’s host Application Processor.
Taken b) Verify Workstation Processor’s host Application Pro-
cessor (smdh_spf ).
c) Make sure no other WPs are running the CIO con-
d) Make sure no other WPs are running the Equipment
DISABLE UPLOAD Action Not a) Verify station’s host Application Processor.
Taken b) Verify Workstation Processor’s host Application Pro-
cessor (smdh_spf ).
ENABLE Action Not a) Verify station’s host Application Processor.
DOWNLOAD Taken b) Verify Workstation Processor’s host Application Pro-
cessor (smdh_spf ).
40
Table 2-19. Station Equipment Changes – Fault Location (Continued)

DISABLE Action Not a) Verify station’s host Application Processor.
DOWNLOAD Taken b) Verify Workstation Processor’s host Application Pro-
cessor (smdh_spf ).
Peripheral Equipment Changes – Fault Location Table

This Fault Location Table addresses the OPERATOR ACTION fields on the Peripheral Change Option
Display and contains recommended check procedures. The table describes interpretations of
fields on this Equipment Information screen and may not be the total solution to an existing
peripheral problem. If further assistance is needed, contact appropriate Foxboro service personnel
(refer to Figure 2-21).
Figure 2-21. Peripheral Change Options Display
Table 2-20. Peripheral Equipment Changes – Fault Location

GO ON-LINE Not responding a) Check peripheral hardware.
b) Check station state (on-line, not failed, and so forth).
41
Table 2-20. Peripheral Equipment Changes – Fault Location (Continued)

GO OFF-LINE Not respondinga) Check peripheral hardware.
GENERAL Not responding a) Check peripheral hardware, cables, and so forth.
DOWNLOAD b) Check station state (on-line, not failed, and so forth).
c) Check station’s host Application Processor.
d) Check for appropriate hardware and software type of
peripheral.
DOWNLOAD Not responding a) Check peripheral hardware, cables, and so forth.
peripheral.
EEPROM UPDATE Not responding a) Check peripheral hardware, cables, and so forth.
peripheral.
ENABLE DEVICE Not responding a) Check peripheral hardware.
ALARMING b) Check peripheral state (on-line, not failed, and so
forth).
c) Check station state (on-line, not failed, and so forth).
d) Check configuration information.
INHIBIT DEVICE Not responding a) Check peripheral hardware.
ALARMING b) Check peripheral state (on-line, not failed, and so
forth).
UPLOAD Not responding a) Check peripheral hardware.
DATABASE b) Check peripheral state (on-line, not failed, and so
forth).
RUN A – ENABLED Action Not Taken a) Check station state (on-line not failed, and so forth).
RUN B – ENABLED b) Check FBM state (on-line, not failed, and so forth).
c) Check PIO cable states (hardware).
RUN AB PERIODIC This is an automatic default mode that switches busses at one hour intervals.
If a problem exists with either A or B bus, the system switches to
RUN–ENABLED on the good or best bus. The system returns to
AB PERIODIC when the bus problem is corrected.
RUN A – DISABLED Action Not Taken a) Check station state (on-line, not failed, and so forth).
RUN B – DISABLED b) Check FBM state (on-line, not failed, and so forth).
c) Check PIO cable states (hardware).
42
Table 2-20. Peripheral Equipment Changes – Fault Location (Continued)

(UIO and UFM only) . LOC (local) a) Clear UNACK bit (use ACK field on Equip Info Dis-
RESET ATTN BIT . FLK (flunk) play for Peripheral.
. Loss of power to b) Reset ATTN BIT from Equip Change Display for
station or Peripheral.
peripheral
NOTE
Reset ATTN BIT is only selectable if it currently needs to be reset.
Station Equipment Information – Fault Location Table

This Fault Location Table addresses only those PARAMETERS on the information display that
need explaining or have recommended check procedures. The table describes the fields on the
Equipment Information screens and may not be the solution to an existing station problem. The
information shown in the following two displays is similar for other types of stations. Caution
should be applied when addressing these parameters and action should be performed only by
qualified personnel. If further assistance is needed, contact appropriate Foxboro service personnel.
Figure 2-22. Equipment Information Display for Station
43
Figure 2-22. Equipment Information Display for Station (Continued)
Table 2-21. Station Equipment Information – Fault Location
Parameter Status Explanation/Check Procedures

RUN MODE Off-line a) Check station hardware.
b) Check software installation.
c) Check related fields:
DIAG STATE
EE UPDATE STATE
DOWNLOAD STATE
FAIL STATE Failed a) Check station hardware.
b) Check communication path between the station
and its system monitor.
ALARMING STATE Not Check station hardware.
Acknowledged
FAIL ACK STATE Not Check printed/historicized log for type of failure.
Acknowledged (To clear, select ACK or ACK ALL on the configured
Workstation Processor.)
FT STATE Non-Operational Check primary and shadow mode fields, or Equip-
ment Information screen for state of individual
module.
44
Table 2-21. Station Equipment Information – Fault Location (Continued)

FAIL DEV ATT Yes One or more of the peripherals attached have
failed. Check out peripherals.
FAIL DEV ACK Not One or more of the peripherals attached have
Acknowledged failed. Check out peripherals. (To clear the failure
and * on station, select ACK or ACK ALL on the con-
figured Workstation Processor.)
DIAG STATE Diagnostic a) Module in OLDD. (OLDD tests are available to
diagnose failures.)
b) Perform restart in Off-line Diagnostic Display.
EE UPDATE STATE Updating Module performing firmware update.
DOWNLOAD STATE Downloading Station is rebooting.
MT REPORT STATE Enabled This station is capable of Supporting a Master
Timekeeper and the master is currently active.
MT REPORT STATE Not Enabled This station is capable of supporting a Master
Timekeeper and the master is currently inactive.
MT REPORT STATE Not Configured This station is not configured to support a Master
Timekeeper.
ATTACH STATE Not Used.
SM REPORT STATE Report All All event and counters are reported.
Report No Events only are reported.
Counters
No Reporting No reporting of events or counters.
EVENTS Yes or No Not supported.
OUTSTAND
PRIMARY MODE Single Prim Only one of the fault-tolerant modules is running.
or Check the shadow hardware. Check the interlink.
SHADOW MODE
(FT Stations only) Married Prim Both modules running are married. This one is
primary.
EE Updating Module updating firmware.
Downloading Module downloading image.
Failed a) This module has failed.
b) Check module hardware.
c) Check the interlink.
Diags Active Diagnostics active on this module.
Married Shadow Both modules running are married. This one is
shadow.
45
Peripheral FBP10 (Fieldbus Cluster I/O Subsystem) – Fault Location

Information
The Fieldbus Cluster I/O Subsystem FBP10 Equipment Information Displays, including the
DIAG STATUS and other fault information fields are described in the Fieldbus Cluster I/O User’s
Guide (B0193RB).
Peripheral FBP11 Through FBP14 (SPECTRUM Control Integrator) –

Fault Location Information
The SPECTRUM Migration Integrator FBP11 through FBP14 Equipment Information Dis-
plays, including the DIAG STATUS and other fault information fields, are described in the
SPECTRUM Migration Integrator User’s Guide (B0193RC).
Peripheral FBM Information – Fault Location Table

need explaining or have recommended check procedures. The table describes interpretations of
the fields on the Equipment Information screens and may not be the total solution to an existing
FBM problem. If further assistance is needed, contact the appropriate Foxboro service personnel.
Caution should be applied when addressing these parameters and action should be performed
only by qualified personnel.
Figure 2-23. Equipment Information Display for FBM
46
Figure 2-23. Equipment Information Display for FBM (Continued)
Table 2-22. Peripheral FBM Information – Fault Location

RUN MODE Off-line a) Check hardware.
b) Download if necessary (that is FBM).
c) Check related fields (DOWNLOAD,
EEPROM UPDATE).
DEVICE STATE Failed a) Check peripheral hardware.
c) Check PIO bus and FBM.
ALARMING STATE Not Responding Check hardware.
DOWNLOAD STATE Downloading Peripheral is rebooting (no problem).
DIAG STATUS 1
DIAG STATUS 2 For descriptive information concerning the status bits that appear on the
Peripheral Information screen, refer to the System Management Dis-
DIAG STATUS 3
plays Help screens.
DIAG STATUS 4
LAST CABLE Not Successful Indicates a PIO Bus send failure.
ACCESS
47
Table 2-22. Peripheral FBM Information – Fault Location (Continued)

PERIODIC Enabled System determines both buses have equal number
SWITCHING of FBM failures. (The primary bus switches
periodically.)
Primary FBM Not Enabled System selects the better bus. This allows auto-
matic switching (due to fault) to Run A or
B mode to occur.
Intelligent Field Device Information – Fault Location Table

IT problem. Refer also to the Intelligent Transmitter Equipment Information Display descrip-
tions in the Measurement Integration (B0193RA) manual for error codes information for the vari-
ous intelligent transmitters. If further assistance is needed, contact the appropriate Foxboro
service personnel. Use caution when addressing these parameters. Action should be performed
only by qualified personnel.
Figure 2-24. Equipment Information Display for Intelligent Transmitter
48
Figure 2-24. Equipment Information Display for Intelligent Transmitter (Continued)
Figure 2-24. Equipment Information Display for Intelligent Transmitter (Continued)
49
Table 2-23. Intelligent Field Device Information – Fault Location

EEPROM UPDATE).
c) Check PIO bus and FBM.
FAIL ACK STATE Not Check printed/historicized log for type of fail-
Acknowledged ure. (To clear, select ACK or ACK ALL on the con-
figured Workstation Processor.)
DIAGNOSTIC ERROR ROM Checksum Take transmitter off-line and place on-line again.
(820 and Vortex) Error (Code 2) If code still exists, replace the amplifier.
EEPROM check-
sum Error (Code 3)
DIAGNOSTIC ERROR Fatal Input Range Take transmitter off-line, place on-line again.
(820 and Vortex) Error Code 7 If error code still exists, replace the sensor.
(Cont.)
DIAGNOSTIC ERROR Arithmetic Take transmitter off-line, and place on-line
(820 and Vortex) Error (Code A) again. If error code still exists replace amplifier.
(Cont.) or
Real Time Clock
Error (Code B)
50
Table 2-23. Intelligent Field Device Information – Fault Location (Continued)

DIAGNOSTIC ERROR Code 02 ROM Checksum error.
(Magflow) Replace transmitter.
Code 0C Hardware failure.
Replace Transmitter.
Code 0D Shorted wire or switch failure.
Replace transmitter.
Code 10 Amplifier malfunction.
Code 11 Amplifier malfunction.
Code 12 Malfunction in coil, amplifier, or electrodes.
Check wiring.
Code 13 Electrodes error, or wiring problem.
Check wiring and clean electrodes.
Code 14 Intermittent in coil, open wire, or low drive.
Check wiring.
Code 1B External RAM test failed.
Code 20 Underrange.
Wired or installed backwards.
Code 21 Overrange.
High flow exists.
Code 22 Overrange.
High flow exists.
Code 30 Factory calibration data lost.
Code 31 Invalid user data (P1-P5).
Reenter data.
Code 32 Invalid user data (HHT).
Reenter data.
XMTR STATUS Bit 2 set If the 1 does not automatically return to 0
NO. 1 within two screen update cycles, place the trans-
(820 and Vortex) mitter off-line. Return the transmitter on-line
from the Equipment Change Display. If 1 still
appears in the bit position turn the transmitter
power off by disconnecting and then reconnect-
ing one of the leads attached to FBM18. If 1 still
appears, the transmitter must be replaced.
Bit 4 set Formula is invalid. Perform a Restore All from
the HHT.
51
Table 2-23. Intelligent Field Device Information – Fault Location (Continued)

XMTR STATUS Bit 1 set If the 1 does not automatically return to 0
NO. 2 within two screen update cycles, place the trans-
(820 and Vortex) mitter off-line. Return transmitter on-line from
the Equipment Change Display. If 1 still appears
in the bit position, turn the transmitter power
off by disconnecting and then reconnecting one
of the leads attached to FBM18. If 1 still
appears, replace the transmitter.
Bit 2 set A bad message was received. This should not
occur. If the bit is set to 1, repeat the check pro-
cedure described for Bit 1 Set.
Bit 3 set Bad function error. Similar to Bit 1 and Bit 2.
Repeat Bit 1 and Bit 2 Set check procedures.
Bit 5 set Primary measurement error. If reinitialization
and/or a power cycle does not clear this error, the
amplifier is bad, the sensor is bad, or the ampli-
fier to sensor connections are bad.
Bit 6 set Totalized flow has exceeded six digits in length
(over 99999 units).
Bit 7 set Failed temperature measurement. Repeat Bit 1
check procedures.
TRAN STATUS Bit 4 set The transmitter initializes during a couple scan
NO. 1 cycles after being put back on-line. The bit may
(Magflow) also be set if there is a diagnostic error.
XMTR STATUS Bit 5 set Thermocouple or RTD failed.
NO. 2 Bit 6 set RTD 2 failed.
(Magflow) Bit 7 set If bit does not clear after Off-line/on-line, then
power cycle. Replace transmitter.
HIU Information – Fault Location Table

This Fault Location Table addresses only those PARAMETERS on information display that need
explaining or have recommended check procedures. The table describes interpretations of the
fields on the Equipment Information screens and may not be the total solution to an existing
HIU problem. If further assistance is needed, contact the appropriate Foxboro service personnel.
Use caution when addressing these parameters. Action should be performed only by qualified per-
sonnel.
52
Table 2-24. HIU Information – Fault Location

b) Download if necessary.
EEPROM UPDATE).
c) Check Fieldbus and HIU.
DOWNLOAD STATE Downloading Station is rebooting (not a fault).
FAIL DEV ATT Yes One or more of the peripherals attached have
failed. Check out peripheral.
FAIL DEV ACK Not One or more of the peripherals attached have
Acknowledged failed. Check out peripherals. (To clear the failure
and * on station, select ACK or ACK ALL on the
configured Workstation Processor.)
LAST CABLE ACCESS Not a) Indicates a PIO Bus send failure.
Successful b) Check PIO Bus. Switch to the other cable if
bus is bad.
DIAG STATUS 1 For descriptive information concerning the status bits that appear on
DIAG STATUS 2 the Peripheral Information screen, refer to the Measurement Integra-
DIAG STATUS 3 tion (B0193RA) document.
DIAG STATUS 4
53
Figure 2-25. Equipment Information Display for HIU
Figure 2-25. Equipment Information Display for HIU (Continued)
54
FD Gateway Peripheral Information – Fault Location Table

This Fault Location Table addresses only those PARAMETERS on information display that need
explaining or have recommended check procedures. The table describes interpretations of the
fields on the Equipment Information screens and may not be the total solution to an existing
FDG problem. If further assistance is needed, contact the appropriate Foxboro service personnel.
Use caution when addressing these parameters. Action should be performed only by qualified per-
sonnel.
Table 2-25. FD Gateway Peripheral Information – Fault Location

c) Check related fields (DOWNLOAD, EEPROM
UPDATE).
FAIL STATE Failed a) Check peripheral hardware.
c) Check Fieldbus and FDG.
Acknowledged (To clear, select ACK or ACK ALL on the configured Work-
station Processor.)
Figure 2-26. Equipment Information Display for Device Integrator Peripherals
55
INTERSPEC Integrator Translator Information – Fault Location Table

INTERSPEC Integrator or INTERSPEC Integrator Translator problem. If further assistance is
needed, contact the appropriate Foxboro service personnel. Caution should be applied when
addressing these parameters and action should be performed only by qualified personnel.
Table 2-26. INTERSPEC Integrator Translator Information – Fault Location

UPDATE).
c) Check INTERSPEC Bus and INTERSPEC Device.
station Processor.)
DIAG STATUS 1 For descriptive information concerning the status bits that appear on the
DIAG STATUS 2 Peripheral Information screen, refer to the System Operations Guide
(B0193CR).
SWITCHING M Enabled Automatic switching of buses on PIO bus failure.
ODE Not Enabled No automatic switching of buses on PIO bus failure.
56
Figure 2-27. Equipment Information Display for INTERSPEC Integrator Translator
INTERSPEC AIM Peripheral Information – Fault Location Table

INTERSPEC AIM peripheral problem. If further assistance is needed, contact the appropriate
Foxboro service personnel. Use caution when addressing these parameters. Action should be per-
formed only by qualified personnel.
57
Figure 2-28. Equipment Information Display for INTERSPEC AIM Peripheral
Figure 2-28. Equipment Information Display for INTERSPEC AIM Peripheral (Continued)
58
Table 2-27. INTERSPEC AIM Peripheral Information – Fault Location

UPDATE).
c) Check INTERSPEC Bus and INTERSPEC Device.
Acknowledged (To clear, select ACK or ACK ALL configured Workstation
Processor.)
LAST CABLE Not Successful a) Indicates a PIO Bus send failure.
ACCESS b) Check INTERSPEC Bus. Switch to the other cable
if bus is bad.
A/D CONVERTER Not OK This indicates an A/D failure.
BATTERY BACKUP Not OK This indicates a battery backup failure.
DP10 Not OK This indicates loss of DP10 power.
SYSTEM FLUNK Flunked This indicates a system flunk.
SYSTEM POWER Not OK This indicates a loss of system power.
PORT 1 FLUNK Flunked This indicates a Port 1 flunk.
PORT 2 FLUNK Flunked This indicates a Port 2 flunk.
INTERSPEC UIO Peripheral Information – Fault Location Table

INTERSPEC UIO peripheral problem. If further assistance is needed, contact the appropriate
Foxboro service personnel. Caution should be applied when addressing these parameters and
action should be performed only by qualified personnel.
Table 2-28. INTERSPEC UIO Peripheral Information – Fault Location

UPDATE).
c) Check INTERSPEC Bus and INTERSPEC
Device.
59
Table 2-28. INTERSPEC UIO Peripheral Information – Fault Location (Continued)

LAST CABLE ACCESS Not Successful Indicates a PIO Bus send failure.
Check INTERSPEC Bus. Switch to the other cable
if bus is bad.
CONTROL PANEL Not OK This indicates that the control panel is in the
SET Off-line mode.
SYSTEM FLUNK Not OK This indicates a system flunk.
SPEC 200 POWER Not OK This indicate loss of SPEC 200 power.
ATTN BIT STATE Not Set This indicates a one or more I/O components may
have experienced memory contents changes as a
result of (1) momentary power failure, (2) flunk
condition, or (3) the UIO module being momen-
tarily switched to Off-line mode at the service
panel.
OVERRUN Not Set Indicates a loss of characters.
COUNTER
Figure 2-29. Equipment Information Display for INTERSPEC UIO Peripheral
60
Figure 2-29. Equipment Information Display for INTERSPEC UIO Peripheral (Continued)
Allen-Bradley Peripheral Information – Fault Location Table

NOTE
For the fault location tables for the Allen-Bradley Station, refer to
“Allen-Bradley Station Equipment Information – Fault Location Table” on page 64.
Allen-Bradley peripheral problem. If further assistance is needed, contact the appropriate Foxboro
service personnel. Caution should be applied when addressing these parameters and action should
be performed only by qualified personnel.
61
Table 2-29. Allen-Bradley Peripheral Information – Fault Location

EEPROM UPDATE).
c) Check PIO bus and A-B PLC.
FAIL STATE Failed a) Check Software.
Primary A-B or ECBP b) Check for Gateway Station.
FAIL ACK STATE Not acknowledged Check printed/historicized log for type of failure.
(To clear, select ACK or ACK ALL on the configured
DOWNLOAD Downloading Failure indication appears on the message line at
STATE top of screen. If so:
a) Check path with the A-B.
b) Check A-B hardware.
c) Check peripheral hardware.
d) Check configuration information
(System Configurator).
DIAG STATUS 1 For descriptive information concerning the status bit that appear on the
DIAG STATUS 2 Peripheral Information screen, refer to the System Management Displays
DIAG STATUS 3 (B0193JC).
DIAG STATUS 4
LAST CABLE Not Successful a) Indicates a PIO send failure related to this
ACCESS A-B PLC.
b) Check PIO Bus.
For information on the Allen-Bradley integrators refer to the document Integrators for Allen-
Bradley Controllers (B0193RG).
62
Figure 2-30. Equipment Information Display for Allen-Bradley Peripheral
Allen-Bradley Redundant ECB Information – Fault Location Table

Allen-Bradley Redundant ECB problem. If further assistance is needed, contact the appropriate
Foxboro service personnel. Caution should be applied when addressing these parameters and
action should be performed only by qualified personnel.
Table 2-30. Allen-Bradley Redundant ECB Information – Fault Location

UPDATE).
c) Check PIO bus and A-B PLC.
FAIL STATE Failed Check Software.
Primary A-B or ECBP Check for Gateway Station.
63
Table 2-30. Allen-Bradley Redundant ECB Information – Fault Location (Continued)

station Processor.)
LAST SWITCH Failed a) Indicates failure to switch to other redundant gateway.
b) Check hardware.
c) Download if necessary.
OPERATION STATE State: Action:
CTL Updating all compounds/blocks. No action necessary.
TRK Redundant gateway is tracking controlling gateway and
ready to assume control (CTL) as required. No action
necessary.
SBY The ABG-R (redundant) is reloading or has no commu-
nication with the A-B PLCs. No action required.
SBY/FAIL Database failure. Reboot the ABG-R station via the
Equipment Change Display.
Figure 2-31. Equipment Information for Allen-Bradley Redundant Gateway
Allen-Bradley Station Equipment Information – Fault Location Table

64
Allen-Bradley Station problem. If further assistance is needed, contact the appropriate Foxboro
service personnel. Caution should be applied when addressing these parameters and action should
be performed only by qualified personnel.
For information on the I/A Series Allen-Bradley Station, refer to Allen-Bradley Station
(B0193MK) document.
Table 2-31. Allen-Bradley Station Equipment Information – Fault Location

c) Check related fields (DOWNLOAD).
FAIL STATE Failed a) Check software.
Primary A-B or ECBP b) Check for gateway station.
FAIL ACK STATE Not acknowledged Check printed/historicized log for type of failure.
(To clear, select ACK or ACK ALL on the configured
RAM STATUS Good or Bad – Bad Refer to PLC documentation.
MAJOR FAULT Bit Pattern Possible hardware failure, refer to PLC
documentation.
MINOR FAULT 1 Fault codes Refer to the PLC documentation for the meaning
and 2 of the codes.
FAULTED Number Rung number executing when fault occurred.
PGM RUNG Refer to PLC documentation.
FAULTED File File containing the ladder program executing
PGM FILE when fault occurred. Refer to PLC
documentation.
FAULT CODE Error code Refer to the PLC documentation for the error
corresponding to the code.
65
Figure 2-32. Equipment Information Display for Allen-Bradley Station PLC-5 Series Peripheral
Allen-Bradley Station Rack Equipment Information – Fault Location Table

Allen-Bradley Station problem. If further assistance is needed, contact the appropriate Foxboro
service personnel.
! CAUTION
Use care when addressing these parameters. This function should be performed only
by qualified personnel.
Table 2-32. Allen-Bradley Station Rack Equipment Information – Fault Location

RACK FAULT Yes Rack configuration is incorrect.
RACK INHIBIT Yes A-B Station does not scan the I/O in an inhibited rack.
RACK QUEUE FULL Yes Block transfer queue is temporarily full – no action required.
RACK RESET Yes Rack outputs are turned off until the RACK RESET is cleared
by PLC. No action required unless there is a PLC fault.
66
Figure 2-33. Equipment Information Display for Allen-Bradley Station Rack
INI 15 Information – Fault Location Table

INI 15 problem. If further assistance is needed, contact the appropriate Foxboro service person-
nel.
! CAUTION
by qualified personnel. Reference Figure 2-34.
67
Figure 2-34. Equipment Information Display for INI 15
Table 2-33. INI 15 Information – Fault Location

RUN MODE Off-line a) Check Printer/Terminal hardware.
b) Check communication path with parent station.
c) Check configuration information.
FAIL STATE Failed a) Check Printer/Terminal hardware.
WP50/WP51 Peripheral Information – Fault Location Table

WP50/WP51 Peripheral problem. If further assistance is needed, contact the appropriate Foxboro
service personnel.
68
! CAUTION
by qualified personnel.
Table 2-34. WP50/WP51 Peripheral Information – Fault Location

RUN MODE Off-line a) Check Printer/Terminal/CPU hardware.
FAIL STATE Failed a) Check Printer/Terminal/CPU hardware.
FAIL ACK STATE Not Check printed/historized log for type of failure.
Workstation Processor.) EG UPDATE STATE Not
Updating.
EE UPDATE STATE Not Updating a) Module not performing firmware update.
Figure 2-35. Equipment Information Display for WP51 Peripherals
69
Figure 2-35. Equipment Information Display for WP51 Peripherals (Continued)
Peripheral Printer/Terminal Information – Fault Location Table

Printer/Terminal problem. If further assistance is needed, contact the appropriate Foxboro service
personnel. These parameters should be performed using caution by qualified personnel (see
Figure 2-36).
70
Figure 2-36. Equipment Information Display for Printer/Terminal
Table 2-35. Peripheral Printer/Terminal Information – Fault Location

RUN MODE Off-line a) Check Printer/Terminal hardware.
FAIL STATE Failed a) Check Printer/Terminal hardware.
FAIL ACK STATE Not Check printed/historized log for type of failure
Memory Parity Errors and I/A Series Station Response

Memory Parity Errors
Although they rarely occur, memory parity errors do occur in all DRAM (Dynamic Random
Access Memory) and Static RAM-based electronic equipment. Parity errors can occur for a num-
ber of reasons, including:
♦ Failed memory cells
♦ Weak cells
71
♦ Alpha particle radiation.

The resulting failure is either a “hard” failure where permanent damage to the IC keeps its mem-
ory cells from properly holding a charge, or a “soft” error, where there is a temporary loss of a
memory cell charge caused by a transient condition.
Refer to “FBM Memory Parity Error Rates for I/A Series Stations” on page 122, and “Module
Replacement Policy for Hard Parity Error Failures” on page 123.
I/A Series Station Response to Parity Errors

I/A Series stations can incur memory parity errors as a result of DRAM failures. The type of
memory parity failure, either hard or soft, determines the resulting station response. In either case,
the station attempts to automatically reboot to clear the parity condition. Memory diagnostics are
run during reboot. If the error is soft, the station passes the memory diagnostics and returns to the
GREEN LED operational state.
Fault-tolerant I/A Series stations can continue to operate under either hard or soft memory parity
conditions. If there is a hard error in one of the station modules, the station continues to run sin-
gle without interruption until its failed RED LED partner module is replaced. If the error is soft,
the module with the error reboots and remarries its partner automatically, without process inter-
ruption.
Single control processors and gateways continue to operate only under soft memory parity error
conditions, after an automatic reboot. During the reboot, control station and gateway outputs go
to their failsafe configured states. After a successful station reboot, the outputs either stay at their
failsafe states or return to control depending on the configuration options selected.
If the memory parity error is hard, the single station fails the diagnostics and goes to the RED
LED operational state, and in the case of control stations and gateways, the outputs remain in
their failsafe states until the module is replaced.
Single workstations continue to operate only under soft memory parity error conditions after an
automatic reboot. After a successful reboot, the workstation automatically returns to the initial
display.
Single application processors continue to operate only under soft memory parity error conditions
after an automatic reboot. After a successful reboot, the application processor resumes normal
operation as defined in the VENIX and application start-up files.
I/A Series FBM Response to Memory Parity Errors

Fieldbus Modules (FBMs) use Static RAM. FBMs continue to operate only under soft memory
parity error conditions, after a watchdog timeout and reinitialization. During the watchdog time-
out and reinitialization, the FBM returns to the normal mode, and the outputs are under the con-
trol of the control processor. If the memory error is hard, the FBM fails to the RED LED state
and the outputs remain in their failsafe states until the module is replaced.
NOTE
If soft memory parity errors occur other than infrequently, external conditions may
be introducing electrical noise and/or extreme temperature to system modules. If
soft errors occur with more than one system module, it is likely that external noise
or temperature conditions are present.
72
3. Corrective Maintenance
This chapter covers corrective maintenance procedures for I/A Series equipment. It describes the
meanings of various stations’ LED indicators, provides care and replacement instructions of
various equipment components, and also provides a collection of equipment troubleshooting
guides.
Information presented in this section is intended to aid field service and maintenance personnel
in determining the source of failures in I/A Series equipment, and to provide procedures to cor-
rect the problem. Becoming familiar with these procedures in advance facilitates efficiency in cor-
rective maintenance later.
Module Status Indicators

Power, Processor, and Fieldbus Modules
All power modules, Processor 10, 20, 30, and 40 modules, LAN modules, and Fieldbus Modules1
have red and green status indicators that operate in accordance with the following code:
Table 3-1. Status Indicators
Red Green Status

OFF ON Operational (no known fault).
OFF OFF No power, or a fault exists in which the green or red LED is
not turned on.
ON ON Startup, or fault exists in which green LED is not turned off
(NOTE: On power-up, the default condition of both LEDs
is ON). Once the system is running, software turns off the
red LED. This condition must last less than two seconds.
ON OFF Failed.
The termination connector on a digital Fieldbus Module has 16 yellow LEDs that illuminate
when their associated channels are active.
DNBI/DNBT/DNBX Modules
In addition to the status indicators listed in Table 3-1, the Dual Nodebus Interface (DNBI), the
Dual Nodebus 10-BaseT Interface (DNBT) and Dual Nodebus Extender (DNBX) modules have
red and green indicators which operate as follows:
♦ DNBI – After the microcontroller successfully completes its initialization procedure,
the red LED is off and the green LED is on. There are, however, two exceptions:
♦ If CTS is not detected (that is, an inactive serial bus), the LEDs are: red = on,
green = on, with one wink.
1.
The Fieldbus Modules have the red and green LEDs on their termination connectors.
73
B0193AD – Rev R 3. Corrective Maintenance
♦ If AUI-PRES is not detected (that is, an inactive AUI bus), the LEDs are: red =
on, green = on, with two winks.
♦ If Jabber condition is detected, the LEDs are: red = on, green = on, with three
winks.
♦ DNBX – When power is applied to the DNBX, the red LED comes on. When the
top connector/actuator is elevated and valid letterbugs are installed, the red LED goes
out and the green LED comes on. If the module’s controller fails, a red-only condition
persists even after the other conditions are met.
♦ If CTS is not detected (that is, an inactive serial bus), the LEDs are: red = on,
green = on, with one wink.
♦ If Ethernet coaxial cable is broken or improperly terminated, the LEDs are: red =
on, green = on with two winks.
♦ If Jabber condition is detected, the LEDs are: red = on, green = on, with
three winks.
♦ DNBT – When power is applied to the DNBT, the red LED comes on. When it
passes its startup diagnostic, and it detects a valid letterbug, the red LED goes off and
the green LED comes on regardless of the state of the elevator connector. A jabber
causes a green LED triple wink condition. An active LINK LED indicates a proper
host-to-DNBT Eternet connection.
NOTE
A “wink” is a 200 ms period of off time in a mostly active LED.
LAN Z-Modules
The LED indicators under the indicator cover of the LAN Z-Modules (shown in Figure 3-1),
have the following meanings, reading from top to bottom on the module. The letters in parenthe-
ses are silk-screened next to the corresponding LED.
♦ Transmit A (TXA) – A green LED indicates transmission on carrierband LAN
Cable A.
♦ Receive A (RXA) – A green LED indicates reception from carrierband LAN Cable A.
This LED is active whenever TXA is active because the modem receives its own
transmission.
♦ Check A (CHKA) – A yellow LED indicates an error on Channel A, either:
♦ Jabber time out (transmission exceeded 0.5 seconds), or
♦ Error receiving data
♦ Transmit B (TXB) – A green LED indicates transmission on carrierband LAN
Cable B.
♦ Receive B (RXB) – A green LED indicates reception from carrierband LAN Cable B.
This LED is active whenever TXB is active because the modem receives its own
transmission.
♦ Check B (CHKB) – A yellow LED indicates an error on Channel B from either:
♦ Jabber time out (transmission exceeded 0.5 seconds), or
74
3. Corrective Maintenance B0193AD – Rev R
♦ Error receiving data
Z-Module
TXA
RXA
CHKA
TXB
RXB
CHKB
Module Status
Indicators
Indicator Cover Indicator Cover (Raised Position)
(Lowered Position)
Figure 3-1. LAN Module Status Indicator Location
Fiber Optic Nodebus Extender Module

The following LEDs are located at the front of the FONBE module. (TX, RX, and LINK MON
are located under the module’s front cover.)
Table 3-2. FONBE Module
Name Color Meaning

TX Yellow Fiber optic transmit activity is present.
RX Yellow Fiber optic receive activity is present.
LINK MON Green Normally on. Indicates that fiber link is intact and that sufficient
receive optical power is available.
- Red Red indicates clock, module, optical power, or other fault.
- Green Green “only” indicates sufficient clock signal and power. Green
and red indicates a major malfunction requiring module replace-
ment. (See “Fiber Optic Nodebus Extension Troubleshooting
Guide” on page 121.)
75
AP20 Module
Figure 3-2 shows the location of, and describes the module LEDs.
3
4
6
11
7
10
8
Item Description
1 Reset Switch – (see following paragraph).
2 Top Captive Mounting Screw (2 Places).
3 Termination Active Indicator illuminates when the terminator is activated.
4 Connector Engagement Actuator (for SCSI Bus).
5 Z-bus Connector (Do Not Remove).
6 Termination Control Letterbug as follows:
T or U in this
Blanks 0 T
position
7 SCSI Bus Activity Indicator (Amber LED). When illuminated, the LED
indicates the AP20 is busy (active) with the SCSI Bus.
8 Termination Check Indicator (Green LED).
9 Bottom Captive Mounting Screw (2 Places).
10 Diagnostic LEDs (Green and Red) (refer to “Power, Processor, and Fieldbus
Modules” on page 73).
11 System Letterbug (set per system requirements).
Figure 3-2. Application Processor 20 Z-Module
76
Reset Switch
A reset switch is provided (recessed below the top captive mounting screw on the right half of the
module). This switch can be activated with a small diameter tool. Press and hold the switch for at
least ten seconds to properly restart the module.
! CAUTION
Do not reset the AP20 unless it is in single-user mode, or the AP20 is unresponsive.
Failure to heed this caution can result in file system corruption. Shut the AP20
down to single user mode (maintenance level) prior to resetting it whenever possi-
ble.
120 MB Hard Disk Module

The 120 MB Hard Disk Drive module has two LED indicators. The Disk Activity (amber) LED
comes on whenever a disk access (read/write operation) occurs. The Power (green) LED indicates
power is applied to the unit. (A blinking Power LED indicates that the proper letterbug characters
have not been inserted.)
I/A Series Module Replacement

I/A Series modules consist of the following:
♦ Processor 10, 20, 30, and 40 Modules
♦ 50 Series Modules (A-, B-, C-, and D-size modules)
♦ Fieldbus Modules
♦ Fieldbus Isolator Modules
♦ Industrial Power Modules.
The I/A Series maintenance approach is oriented toward module replacement. Chapter 2 “Fault
Analysis” provides assistance with isolating station and peripheral faults. The presence of status
lamps (LEDs) on each module enables an initial detection of problems that can exist on the mod-
ule level. In addition, any module can be replaced without affecting the operation of any other
module, including the other module of a fault-tolerant pair.
Replacement of I/A Series modules is similar to module installation, which is described in the Sys-
tem Equipment Installation (B0193AC) document. Refer to that document for replacement proce-
dures.
! CAUTION
Before replacing any I/A Series module, consider the power backup configuration
and on-line application, so as not to disturb the process.
FBM Replacement using the Output Bypass Station

During the process of replacing a non-redundant analog output FBM (FBM04, 06, 22, 37, 39, or
44 used in a non-redundant configuration), the Output Bypass Station (OBS) is used to transfer
the outputs to standby (manual) control.
77
To remove a non-redundant analog output FBM, proceed as follows:
NOTE
The following procedure does not apply to redundant FBMs. To use the OBS to
effect control of redundant FBM outputs, refer to “Fieldbus Module (FBM) Trou-
bleshooting Guide” on page 105.
! CAUTION
1. The following procedure requires switching of FBM analog outputs to “Manual.”
Before performing this procedure, take any necessary measures to ensure that the
switch to manual does not adversely affect the process under control.
2. To minimize any bump in the process, each mode switch on the OBS must be in
the “N” (Normal) position before inserting the plugs into the FBM. There is a
momentary bump when inserting and removing each plug, and when switching the
mode switch.
1. Connect the OBS to the FBM to be replaced, as shown in Figure 3-3, taking note of
the following:
a. Normally, the OBS output plugs are connected to all four output jacks of the
FBM, to allow removal of the FBM while maintaining manual control of the out-
puts to the field devices.
b. The red output cable corresponds to Mode Switch 1, Output Adjustment 1, and
the associated meters. Likewise, the green output cable corresponds to Mode
Switch 2, Output Adjustment 2, and the associated meters.
2. For each of the four FBM outputs:
a. From the I/A Series process operations displays, switch the analog output block to
Manual.
b. Vary the output adjustment on the OBS for a null (center-scale) reading on the
deviation meter.
c. Place the mode switch on the OBS in the “S” (Standby) position.
3. Having made the transfer to Standby (manual) control for each output, from the
I/A Series System Management Displays switch the FBM to “off-line.”
4. The TCA can now be detached from the FBM, and the FBM can be removed from
the mounting structure. (While in the Standby mode, the OBS is acting as the FBM.)
78
Output Bypass Station* Analog Output FBM**
Deviation Meter 1 Red (#1) Red (#1)

Output Meter 1
Green (#2) Green (#2)
Output Adjust 1
N N
S Mode Switch 1
S
Deviation Meter 2
Output Meter 2
Output Adjust 2
N N
S Mode Switch 2
S
*The Output Bypass Station contains two modules, as shown.

**FBM04, 06, 22, 37, 39, or 44 used in a non-redundant configuration.
Figure 3-3. Connection of Output Bypass Stations to FBM
To install a new FBM, proceed as follows:

1. Place the FBM in the mounting structure and attach the TCA.
2. From the I/A Series System Management Displays, place the FBM on-line.
3. For each of the four FBM outputs:
a. Using the I/A Series process operations displays, manually adjust the analog out-
put block’s output to obtain a null reading on the associated OBS deviation meter.
b. Place the mode switch on the OBS in the “N” (Normal) position.
4. With all four outputs nulled and switched to Normal, disconnect the output plugs
from the FBM.
5. The FBM outputs may now be switched to “Auto” (from the I/A Series process opera-
tions displays) to resume normal I/A Series control.
I/O Static Discrete Submodule Replacement

Static Discrete Signal Conditioning I/O submodules are color coded by the type of voltage isola-
tion they provide, with red and black denoting dc and ac outputs, respectively, and white and yel-
low denoting dc and ac inputs.
79
! CAUTION
All external 115/230 V ac power sources must be turned off at the main before han-
dling the submodules. In addition, check that self-powered field wires into the sub-
modules are not live. Check the status LED indicator on the isolator before
proceeding.
A single captive Phillips-head screw passes through the middle of the submodule and attaches to
the DB16 backplane. Pull up firmly on the submodule and remove. Reverse the procedure to
attach a new submodule.
IPM06A and IPM06D Battery Care
Pb
ATTENTION:
The product you have purchased contains a rechargeable battery.
The battery is recyclable. At the end of its useful life, under various state
and local laws, it may be illegal to dispose of this battery into the municipal
waste stream. Check with your local solid waste officials for details in your
area for recycling options or proper disposal methods.
The life expectancy of the sealed lead-acid battery used in the IPM06A (P/N CM902WX) and
IPM06D (P/N CM902WY) depends on a number of variables: temperature, number of
charge/discharge cycles, depth of each discharge, regularity of recharging, and the performance of
the battery charger.
! CAUTION
Failure to keep a battery in a charged condition degrades battery life. If a battery (or
IPM06A/D module containing the battery) is not to be placed into service immedi-
ately, the battery must be recharged every four months. Refer to “IPM06A and
IPM06D Modules Not Immediately Placed Into Service” on page 81.
If proper maintenance is followed, and if the battery is charged correctly during standby use, the
battery capacity does not diminish significantly after performing its function during a power out-
age. To further protect the battery from over-discharge, the IPM06A and IPM06D include a
dropout circuit which disconnects the battery from the load when the voltage becomes too low
(approximately 15 V dc).
80
Battery Charge/Recharge Procedures
! CAUTION
The battery must be recharged in the upright position (arrow on battery always
pointing up). Do not recharge upside down. To accomplish this recharge condition,
the IPM06A or IPM06D module must be placed in the mounting structure.
To prepare the module for charging refer to Figure 3-4 and perform the following steps:
1. Remove battery side access door.
2. Connect the (red) positive (+) battery lead to the (red) positive (+) terminal.
3. Reinstall side access door.
Memory Backup Power Module
Battery
Positive (+) Part Numbers: Positive (+) Lead
Battery
Battery CM902WX (IPM06A) Battery
Lead
Terminal CM902WY (IPM06D) Terminal
Figure 3-4. Disconnecting Positive Battery Lead IPM06A (CM902WX), IPM06D (CM902WY)
Normal Maintenance
NOTE
Foxboro recommends that spare IPM06A and IPM06D Power Modules remain
plugged into an Input Power Bus to remain on trickle charge.
Periodically perform system backup checks on a scheduled maintenance basis (when customer
equipment is being serviced). Alternate spare IPM06A and IPM06D module(s) can be installed
prior to the on-line IPM06A and IPM06D being removed for battery replacement.
IPM06A and IPM06D Modules Not Immediately Placed Into

Service
If a power module is not used immediately:
1. Repeat the battery charge procedure and charge the battery for at least 24 hours.
When you finish charging the battery, refer to Figure 3-4 and perform the following
steps to store the battery:
81
a. Remove battery side access door. Disconnect red positive (+) battery lead from the
(red) positive (+) terminal.
b. Reinstall side access door.
c. Place into a controlled monitored storage area.
2. Record recharging action. Record should include date of current charge, date of next
required charge, and unit serial number.
3. Repeat this process every four months until unit is put into service.
Reinstallation of IPM06A and IPM06D Into Backup Service

1. Remove battery side access door.
2. Reconnect the (red) positive (+) lead to the (red) positive (+) battery terminal.
3. Reinstall side access door.
4. Charge battery within module for at least 12 to 16 hours prior to backup usage.
NOTE
Upon application of power, both red and green LEDs should come on simulta-
neously, indicating a battery charging condition.
IPM06A and IPM06D Battery Replacement

Battery Replacement Kit
A battery replacement kit (P0903RL) is available from The Foxboro Company. Table 3-3 lists the
kit contents. Kit maintenance should be performed in the field. Do not return the modules to the
factory.
Table 3-3. IPM06 (A, D) Battery Replacement Kit
Description Part Number Quantity

Battery P0162DQ 1
Cable Tie X0172QW 2
Instructions B0193PY 1
Equipment Required
You need the following tools to replace the battery:
♦ Cross-point screwdriver, medium head
♦ Cross-point screwdriver, long-shank, small head
♦ Cutting pliers
♦ Flat-blade screwdriver, medium head.
82
Battery Removal/Replacement Procedure for

P/N CM902WX/WY
NOTE
Battery replacement is recommended after 12 to 16 months of service.
! CAUTION
Short circuiting of battery terminals can cause battery to overheat and rupture.
De-energizing Existing Battery

The existing battery in the power module must be de-energized prior to replacement. Refer to
Figure 3-4 and perform the following steps:
1. Locate the battery access cover on the left side of the module. Insert and twist the tip
of a flat-head screwdriver in the slot at the top of the cover. The cover, which is spring
hinged, pops off. Leave the access cover off until you complete the procedure.
2. Disconnect the exposed (red) positive (+) lead from the (red) battery terminal.
Removal and Replacement of Existing Battery

Refer to Figure 3-5 and perform the following steps.
Four (4) Heat Sink Screws Side Cover Screws

(One Each Side)
Nose of Module
(PWA) Charging
Circuitry
Heat Sink Module Chassis

Removed From
Side Covers Red (+) Terminal
Battery
Cable Ties
Figure 3-5. Removing the Rechargeable Battery IPM06A (CM902WX), IPM06D (CM902WY)
1. Using the medium cross-point screwdriver, remove the four screws that fasten the rear
heat sink to the module.
83
2. Using the small cross-point screwdriver, remove the two screws on the side covers on
the module (one on each side cover). Remove the side covers and position the module
to expose the battery from the top.
NOTE
Care must be taken to ensure components on the battery charger circuit board
attached to the module chassis are not damaged during removal of the side covers.
3. Examine and note the battery position and cable ties holding the battery in place. The
positive (+) terminal should be facing the front of the module, and the arrow on the
battery label should be pointing towards the battery seating bracket on the chassis.
4. Disconnect the negative (–) battery terminal lead and cut both cable ties. Remove the
battery.
5. Place the new battery in the seating brackets (arrow on label towards the chassis), not-
ing that the positive (+) terminal is facing the front of the module. Place new cable ties
around the battery and fasten securely.
6. Observing the color code, connect the terminal leads to the battery terminals; (red)
lead to the (red) positive (+) terminal, and the (black) lead to the (blue) negative (–)
terminal.
7. Carefully replace the side covers. Slide the cover edges into the holding slots on the
nose of the module. Be sure both covers are secured to each other by the overlap
flanges. Fasten both covers to module frame with screws. Tighten to 2.5-3.0 inch-lbs.
8. Observing the cover edges and holding slots on the heatsink, replace and fasten the
heatsink to the module chassis. Tighten to 11.5-13.0 inch-lbs.
9. Replace battery access cover on side of module.
10. Charge battery within the power module for 12 to 18 hours prior to initial use.
NOTE
See “Battery Charge/Recharge Procedures” on page 81 for battery recharge
recommendations.
11. Identify module with newly installed battery, record battery service/replacement date,
and retain traceability for future reference.
! CAUTION
The battery used in the IPM06A/D module is a sealed lead type which must be
recycled or disposed of properly. Dispose of (or recycle) old battery in accordance
with country, state or local regulations.
IPM7, 8, 9 Fan Power Module Replacement

Fan power modules (and fan assemblies) are only installed in sealed enclosures. This procedure
that follows applies only to the structural foam enclosures.
84
To replace a fan power module, first remove the fan assembly (see “Fan and Grill Assembly
Replacement” on page 85), then remove the fan power module as follows:
1. Refer to Figure 3-6 (“Fan Power Module and Fan Assembly” on page 86) and
Figure 3-7 (“Field Enclosure 8 (Metal) Fan Assembly Removal” on page 86).
Using the hex driver tool, loosen two quarter-turn captive screws securing one end of
fan grill to enclosure support member. This causes the fan to drop forward if the fan
assembly is mounted at the top of the enclosure. This provides access to the fan power
module cable connector on the fan assembly. If the fan assembly is mounted at the
bottom of the enclosure, it must be lifted up to remove.
2. With the fan still in place, disconnect the power module (phone type) connector from
the fan assembly. Disconnect Status Alarm Connector.
3. Lift up on other end of fan grill until the grill pops out from rail, then remove fan
assembly.
4. Using the hex driver tool, loosen captive screw on front of fan power module. Remove
the module from the input power bus connector by pushing the module straight back,
then either drop the module out (if on top), or lift it up (if at bottom).
5. To install fan power module, reverse the procedure.
Fan and Grill Assembly Replacement

This procedure that follows applies only to the structural foam enclosures. Refer to the end of
this section for the fan assembly removal procedure pertaining to metal enclosures.
1. Refer to Figure 3-6, Fan Power Module and Fan Assembly.
Using the hex driver tool, loosen two quarter-turn captive screws securing one end of
fan grill to enclosure support member. This causes the fan to drop forward if the fan
assembly is mounted at the top of the enclosure. This provides access to the fan power
module cable connector on the fan assembly. If the fan assembly is mounted at the
bottom of the enclosure, it must be lifted up to remove.
2. With the fan still in place, disconnect the power module (phone type) connector from
the fan assembly. Disconnect Status Alarm Connector.
3. Lift up other end of fan grill until the grill pops out from rail, then remove fan assem-
bly.
4. Remove four screws securing grill to fan assembly.
5. To install a new fan assembly, reverse the procedure.
The procedure for removing the FE8 fan assembly for the metal type enclosures is as follows:
1. Refer to Figure 3-7 to locate the assembly and its bolts.
2. At the rear of the assembly, disconnect the power cord from the power receptacle.
3. From both sides, remove a single bolt, holding the assembly. With one hand under-
neath, hold the assembly securely. With the other hand, remove the remaining two
side bolts.
4. With both hands, pull out and remove the assembly from the enclosure.
85
Status Alarm Fan Power

Connector Module
Power Module
Captive
Connector
Screw
Fan
Pins to Input
Power Bus
Grill Captive
Fan Mounting Holes (4 Places)
Screws
Figure 3-6. Fan Power Module and Fan Assembly
Fan Assembly Fan Assembly

Bolts Bolts
Enclosure (Rear View)
Figure 3-7. Field Enclosure 8 (Metal) Fan Assembly Removal
86
Junction Box Circuit Breaker Replacement

Each junction box in an I/A Series enclosure contains a circuit breaker which is used as an On/Off
power switch. Two types of junction boxes are used:
♦ J1 Type – (Figure 3-8) used in Industrial Enclosures 16 and 32, Field Enclosure 8, and
Field Enclosure 4.
♦ J2 Type – (Figure 3-9) used in 1x8 Mounting Structures.
! WARNING
Each junction box contains voltages that are hazardous to human life. Make sure
you turn off input power to the equipment before attempting to remove the circuit
breaker.
For the locations of the junction boxes in the I/A Series equipment, refer to the System Equipment
Installation (B0193AC) document.
To replace a circuit breaker in a J1 type junction box:
1. Turn off power to the equipment.
2. Gain access to the junction box containing the circuit breaker that is to be replaced.
3. Place the circuit breaker switch in the OFF position.
4. Remove top and bottom retaining screws holding cover. Lift and remove cover.
5. Remove the two screws that holds the circuit breaker board. Pull out on circuit
breaker to remove.
6. To install circuit breaker, reverse the procedure.
To replace a circuit breaker in a J2 type junction box:
1. Turn off power to the equipment.
2. Shut off circuit breaker.
3. Remove six screws securing junction box top cover and remove.
4. Lift breaker out to remove. Disconnect leads to the breaker terminals.
5. To install new circuit breaker, reverse the procedure.
87
J1 Type Junction Box
Power Out
Junction Box Connectors
(to Power
Modules)
Power Switch/
Bottom
Junction Box Circuit Breaker
Cover
NOTE: Alternatively, the Junction Boxes can Access Hole

be located on the left side of the enclosure.
Figure 3-8. Industrial Enclosure 16, Junction Box Locations
1x8 Mounting
Structure
J2 Type Junction Box
Power Switches/Circuit
Breakers (Two if Redundant)
Metal Enclosure (Front View)
Figure 3-9. Field Enclosure 8 (Metal) Junction Box Location
Letterbug Replacement
Module identifiers (letterbugs) are inserted in all processor type modules and in termination con-
nectors on Fieldbus Modules. To replace one or more of the letterbugs comprising a module iden-
tifier, refer to the System Equipment Installation (B0193AC) document.
88
AP20 Data Storage Device Replacement

NOTE
On-line replacement of SCSI Bus devices (that is, hard disks, streaming tape drives,
floppy drives) is not allowed because of occurrence of bus errors. The entire disk
backup using the streamer tape copy command (stcopy) must be done with the
Application Processor off-line. This is due to the high speed operation which domi-
nates bus traffic. Interim backups can be accomplished on-line using floppies. An
alternative is to keep a second hard disk on-line to act as a hot spare; however, this
would have an adverse affect on the disk life.
For detailed information concerning the replacement (installation) of these storage devices, and
associated jumper and DIP switch settings, refer to the System Equipment Installation (B0193AC)
document.
NOTE
1. Fault-tolerant Application Processor 20s allow for replacing an Application Pro-
cessor or any peripherals without disturbing normal operation by unmarrying the
fault-tolerant pair before taking the AP or peripheral out of service. Mirrored disks
become resynchronized on-line when the fault-tolerant pair is remarried.
2. Drive jumpers are subject to a position change when the data storage device has
changed position within an enclosure.
Mounting Structure Bus Replacement

The mounting structure bus distributes power and data lines to each module in the mounting
structure. This bus contains both the Nodebus and the Fieldbus. The mounting structure bus fas-
tens in the rear of the mounting structure, and can be removed through the front of any empty
mounting structure.
The following steps are used to remove (or insert) a mounting structure bus from (or into) the
1x8, 2x4, and 2x8 Mounting Structures. This procedure can be considered when all other meth-
ods of diagnosing a problem fail (that is, no status lights and no power to the modules).
1. Before removing the mounting structure bus, check incoming power at the “D” con-
nector from the intermediate power bus. The row and column power is brought in via
the 15-pin miniature “D” connector.
2. If the power is nonexistent, proceed to remove the bus. Disconnect the two “D” con-
nectors at the end of the bus, one on top for the row power, and one for the column
power on the bottom.
3. Disconnect the mounting structure grounding strap connected to the green-wire
ground. A finger on the strap passes into the rear of the mounting structure bus,
bringing the ground to the circuit board assembly.
4. Remove the four screws across the top that fastens the bus to the mounting structure.
Slide the bus out through the front of the structure.
89
5. Reverse Steps 1 through 4 to replace the new bus. Note position of the junction box
and the input power so that the bus is positioned correctly. Molded ribs at the ends of
the bus assist in positioning and aligning the bus when inserting into the mounting
structure
Fault-Tolerant Processor Module Replacement

This procedure defines the steps needed to replace one or both Processor modules in a fault-toler-
ant pair. The following method applies to Control Processors CP30/40 and CP30B/CP40B,
CP60, and the Gateway 30/30B (GW30/30B). For additional information related to module
installation, refer to the Systems Equipment Installation (B0193AC) document.
1. Enter System Management
a. Select <SYS> key from the top menu bar.
b. Select <SYS Mgmt> from the drop down menu bar.
2. Select the station letterbug.
3. Select Offline at the bottom of the screen.
4. Select Primary or Shadow.
5. Verify the module is offline. This will put the selected module in the Off-Line Diag-
nostic state and the other module will continue in the Single Primary State.
6. Remove the Fault-Tolerant Module Connector (refer to the “Front-Mounted Fault-
Tolerant Module Connector Replacement” on page 91).
7. Using a hex driver tool, lower the peripheral connector actuator by turning 1/2 turn
counter clockwise on the module that was taken offline. Unscrew the captive mount-
ing screws and remove the module.
8. Remove the letterbug and insert it into the new replacement Processor module.
9. Insert the new Processor module into the proper slot and tighten the captive mount-
ing screws.
10. Replace the Fault-Tolerant Module Connector and raise the peripheral connector
actuator on the Processor module.
11. Ensure that the modules have booted and married and stayed green for at least three
minutes.
12. Select <RESTART> from the System Management disply to exit out of the offline diag-
nostics.
13. Repeat steps 2 through 11 for the remaining Processor module if necessary.
Rear-Mounted Fault-Tolerant Module Connector

Replacement
The rear-mounted fault-tolerant module connector is used with the fault-tolerant versions of the
X- and Z-Modules.
Inserted into the mounting structure bus on an “as needed” basis, the rear-mounted fault-
tolerant module connector is available in two styles: a short connector (Part Number P0400CV)
90
is used to interconnect two single-width fault-tolerant modules, and a long connector (Part Num-
ber P0500XL) is used to interconnect two double-width fault-tolerant modules.
To remove and replace a connector, proceed with the following steps. Refer to the System Equip-
ment Installation (B0193AC) document for similar details concerning installation.
1. To remove the connector, place the thumb and forefinger on the rear of the connector
near the clips (tabs) and press together. This releases holding tabs on the connector.
Pull connector straight outward and remove from Mounting Structure. If the connec-
tor is a double style type (two singles tied together), then two hands may be needed to
depress the connector.
2. To replace the fault-tolerant connector, insert the tabs into the holes provided and
slide the connector straight inward until clips are properly fastened. A small notch
below the tabs on the connector guides it into place.
Front-Mounted Fault-Tolerant Module Connector

Replacement
The front-mounted fault-tolerant module connector is used with the fault-tolerant version of the
Control Processor 30/40, Control Processor 30B/40B, Gateway 30 and Gateway 30B. To remove
and replace the front-mounted fault-tolerant module connector, proceed as follows. (More
detailed information regarding installation of the connector is presented in the System Equipment
Installation (B0193AC) document.)
! CAUTION
Before removing the fault-tolerant module connector, the station must first be taken
offline using System Management. Refer to “Fault-Tolerant Processor Module
Replacement” on page 90 for instructions on how to take a station offline.
1. Refer to Figure 3-10. For each of the modules in the fault-tolerant pair, lower the
fault-tolerant module connector cover by grasping the cover near the top and pulling
toward you.
2. Grasp the tab on the fault-tolerant module connector, and move it outward (toward
you).
! CAUTION
The tab is provided on the fault-tolerant module connector for safe removal of the
connector. Do NOT remove the connector by grasping its sides, as this can damage
the connector pins.
3. Insert the new front-mounted fault-tolerant module connectors into the two exposed
receptacles at the front of the modules.
4. Raise each of the fault-tolerant module connector covers, and press firmly in place.
91
Z- Module Tab on FT Module

Fault-Tolerant Connector (See CAUTION
Module Connector Statement in Text)
Receptacle
Fault-Tolerant
Module Connector Fault-Tolerant
Cover (Lowered Module Connector Fault-Tolerant Module
Position) Cover (Raised Connector* in Place
Position) (Also attaches to
adjacent module,
not shown)
*FT Module Connector P0960AH used with Control Processor 30, Control Processor 40, and
Gateway 30.
FT Module Connector P0961BS used with Control Processor 30B, Control Processor 40B, Control
Processor 60, and Gateway 30B.
Figure 3-10. Front-Mounted Fault Tolerant Module Connector Replacement
Pin Assignments for the Input Power Bus

The Input Power Bus as used in the I/A Series system eliminates the need for selecting a voltage
range within the power modules by configuring jumpers. The input power bus has pin assign-
ments to ac lines, status lines to monitor module power functions, and RFI grounding points.
The pin assignments vary according to the various voltage types available. Note that only eight of
the twelve contacts are used in any one power module.
Figure 3-11 through Figure 3-13 show the pin assignments available for the various input power
module voltages. These are made available to aid the service personnel in detecting possible prob-
lems associated with the ac lines, power modules failures, and/or RFI grounding points.
Pins 1 and 12 (status lines on all modules) are used to indicate failures on any power module.
These lines are normally high (20 to 30 V dc). Any failed power module pulls the lines down to
0 to 0.25 V dc. The status lines are brought into the power modules from the intermediate power
bus. They continue through the power modules into the input power bus and on to the fan power
modules.
Power modules with ac inputs have Pins 2 and 11 designated as an RFI ground points. Power
modules with dc inputs have Pins 3 and 10 designated as the RFI ground.
92
! CAUTION
Grounding points indicated with the pin assignments are RFI associated only. They
are not considered as a safety ground.
Input Wiring Configuration for Input Power Modules

The input wiring configurations for the various ac and dc input voltages are shown in Figure 3-14
through Figure 3-16. The left side of each diagram shows a portion of the input power bus. The
right side of each diagram shows the input stage of the power module.
These input wiring diagrams are made available to the service personnel to aid detection of a pos-
sible power problem associated with the input power module. Caution should be used in trouble-
shooting these circuits.
Figure 3-11. 100 and 120 V ac Input Power Bus Wiring Diagram
93
Figure 3-12. 220 and 240 V ac Input Power Bus Wiring Diagram
Figure 3-13. 24 and 125 V dc Input Power Bus Wiring Diagram
94
INPUT INPUT
POWER IPM POWER IPM
BUS FRONT BUS FRONT
CONNECTIONS END CONNECTIONS END
Figure 3-14. Power Module 100/120 V ac Input Circuits
Figure 3-15. Power Module 220/240 V ac Input Circuits
95
Figure 3-16. Power Module 24/125 V dc Input Circuits
Processor Module Troubleshooting Guide

This Processor Module Troubleshooting Guide is intended to be a service guide for some of the
most commonly encountered system problems. The suggested steps indicated for each problem
category are only recommended check procedures.
In many cases, problems that surface are faults associated with communication paths (cables, con-
nectors, internal data, and power buses, and so on). On the module level, the quickest way to
determine and correct the problem is by replacement. Spare parts are not always available; thus,
these recommended check procedures may be a practical approach.
! CAUTION
Always reboot modules through System Management (SMDH) if possible, or by
CTL/ALT/F1 for WPs.
Single Module Not Rebooting

An attempt to reboot any single module in the system loop can cause the module’s red and green
lights (LEDs) to turn on. If this occurs, proceed with the following recommended check proce-
dures. Recommended checks need not be followed in order. If one step corrects the problem,
obviously the remainder need not be performed.
1. Check that the top and bottom module captive screws are tightly secure.
2. Check the module letterbug.
a. Make sure the letterbug is properly seated.
b. Install the letterbug into the module upside down.
96
c. Replace the letterbug.

d. Check the boot request via a local area network analyzer.
3. Check elevator connection for proper engaging.
Application Processor 20 Not Rebooting

An attempt to reboot an Application Processor in the system loop may cause the module’s red and
green lights (LEDs) to turn on. If this occurs, proceed with the following recommended check
procedures. Recommended checks need not be followed in order. If one step corrects the problem,
1. Check elevator connection for proper engaging.
2. Check SCSI cabling.
3. Check SCSI bus for proper termination.
4. Check for proper jumper setting on the attached hard drive.
5. Reboot using a “Tape Backup and Restore” diskette, and perform a file system check
to determine hard drive status.
Modules Hosted by an AP Not Rebooting

An attempt to reboot a module hosted by an Application Processor in the system loop may cause
the module’s red and green lights (LEDs) to turn on. If this occurs, proceed with the following
recommended check procedures. Recommended checks need not be followed in order. If one step
corrects the problem, obviously the remainder need not be performed.
1. Reboot the hosting AP.
2. Check the AP letterbug by performing the following:
a. Reboot a WP with letterbug G2BOOT or G3BOOT.
– or –
b. Reboot a COMM10 with letterbug CSBOOT and log into the AP by typing:
call{ap_letterbug}
c. Make sure that the correct AP boots the AP.
d. Type in VT100 mode: uname -n. The correct AP letterbug should be returned.
Replace or reseat the AP letterbug if the correct name is not displayed.
3. If the letterbug is incorrect, or if it can not be determined to be correct, check the AP’s
SCSI bus terminations.
AP Boots, One or More Stations Not Rebooting

If an AP boots and attempts to reboot one or more modules in the system loop causing the mod-
ule’s red and green lights (LEDs) to turn on, proceed with the following recommended check pro-
cedures. Recommended checks need not be followed in order. If one step corrects the problem,
1. Inspect the files: /usr/fox/sp/log.* file for installation errors. The log files have a
nine-digit string that specifies the timestamp. The last log file listed with an
ls -lrt log.* command is the most recent file.
2. Check files: /usr/fox/sp/sldb and /usr/fox/sp/hldb.
a. The station letterbug(s) shown should be correct.
97
b. The host AP letterbug(s) shown should be correct.

3. Check the /usr/fox/sp/files directory to assure that CMX{letterbug}.bin files
exist for the station(s).
4. Perform a delete_sta for the problem stations and reinstall the station(s).
5. Replace the module if all else fails.
Nodebus Extender Failure

If a Nodebus Extender failure in the system loop causes the module’s red light (LED) to turn on,
check the elevator connection for proper engaging. The Nodebus Extender LED shows red unless
the elevator is raised and bus terminated.
General Module Failure

If a general module failure in the system loop causes the module’s red light (LED) to turn on, pro-
ceed with the following recommended check procedures. Recommended checks need not be fol-
lowed in order. If one step corrects the problem, obviously the remainder need not be performed.
1. Remove the module and check it for bent pins.
2. Check for power tolerances.
3. If a failure occurs after five seconds from powerup (or insertion), check the letterbug.
a. Make sure the letterbug is properly seated.
b. Install the letterbug upside down.
c. Replace the letterbug.
4. If a failure occurs within five to ten seconds after power-up (or insertion), verify that
the Mounting Structure (cellbus) termination is correct.
5. Replace the module if all else fails.
Station Uploads
When an upload occurs, a system message is printed on the printer as follows:
--DATE-- --TIME-- 0 SYSMON = -NAME- SNLBUG Software Manager
SYSMON -00023 Memory Dump Successful. File name = SNLBUG.dmp
Where SNLBUG = the letterbug of the station which did the upload (hereafter SNLBUG is used as a
symbol for the actual station letterbug of an uploading station).
Customer Actions After an Upload

The actual file SNLBUG.dmp is found in the directory /usr/fox/sysmgm/softmgr/dump/ of the AP
which hosts the rebooting station. Since the size of these dump files is around 1 MB, it is strongly
recommended that these files be copied to a floppy and then removed from the AP’s hard disk.
The dump file should be copied to a floppy disk. The following sections describe how to collect a
Station Upload for each different station type.
AP20 Uploads
AP20 uploads are always performed on the hard disk of the AP20 which reboots. There are two
files created for the AP20 upload: SNLBUG.1 and SNLBUG.2.
98
1. Insert a formatted diskette into the first disk drive (fh0) of the AP that contains the
dump (this is the AP20 which rebooted). Label the diskette with the following infor-
mation:
♦ SNLBUG.1 using the actual AP Station Letterbug
♦ Date that Station reboot occurred
♦ Station type (AP20)
♦ Customer Site identification
♦ Customer name to contact for further information.
2. Enter the following commands from a WYSE terminal or VT100 mode on a WP:
cd /usr/fox/sysmgm/softmgr/dump
mount /dev/fh0 /f0
cp SNLBUG.1 /f0
umount /dev/fh0
3. When the commands in Step 2 have completed, insert a second formatted floppy into
the first floppy drive (fh0) of the AP with the dump. Label this floppy like the first
one, except identify with SNLBUG.2 using the actual Station Letterbug.
mount /dev/fh0 /f0
cp SNLBUG.2 /f0
umount /dev/fh0
rm SNLBUG.*
CP30/40 and WP30 Uploads

1. Insert a formatted diskette (no file system necessary) into the first disk drive (fh0) of
the AP with the dump (this is the AP which hosts the uploaded CP30, CP40, or
WP30 Station). Label the diskette with the following information:
♦ SNLBUG.1 using the actual CP30/CP40 or WP30 Station Letterbug
♦ Station type (CP30/40 or WP30)
♦ Write word “COMPRESSED” onto floppy
♦ Customer site identification
♦ Customer name to contact for further information
/usr/foxbin/compress SNLBUG.dmp
NOTE
This can take several minutes.
tar cvf /dev/fh0 SNLBUG.dmp.Z

rm SNLBUG.*
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All Other Station Type Uploads

1. Insert a formatted diskette (no file system necessary) into the first disk drive (fh0) of
the AP with the dump (this is the AP which hosts the uploaded station). Label the dis-
kette with the following information:
♦ SNLBUG.1 using the actual Station Letterbug
♦
Station type (CP10, COMM10, Gateway Type, and so forth.)
♦ Customer site identification
♦ Customer name to contact for further information
tar cvf /dev/fh0 SNLBUG.dmp
rm SNLBUG.dmp
Notifying Foxboro of Uploads

When notifying Foxboro of uploads, follow the procedure described in the section “How to
Report Problems to the Foxboro Company” in Operational Recommendations in the release
notes. Any pertinent information about system activity should be noted (database editing in
progress, any special AP processes running, and so forth). The appropriate checklist(s) should be
completed and forwarded with the upload file(s) and other files specified in the checklist(s).
Disabling Uploads
Upload delays the rebooting of a Station (the upload takes about three minutes to complete).
For example, WPs that perform an upload take about five minutes to come up. Also, the upload
function itself takes a process slot in the AP20. If either of these things are unacceptable, upload
can be disabled in two ways. Specific stations can be disabled via SMDH from the Equipment
Change Display for the Station. Upload within a given AP20 can be disabled by killing the
upload_srvr process on the AP20. This can be done by issuing the following commands from a
WYSE terminal or VT100 mode:
ps -e | grep upload
Example results: 184? 0:01 upload_s, where the first field, 184, is in this case the Process ID
(PID).
kill -9 PID
Where PID is the resulting first field number generated from the grep command (184 in the
example above).
To more permanently disable the upload_srvr on an AP, the file /etc/inittab should be edited.
The line containing upload_srvr should be changed from :once: to :off:.
To disable uploads on an AP50, the upload for each station should be disabled individually using
SMDH.
Module Going From Green State to Red/Green State

When a module goes to a Red/Green state from a Green state, the module is in an off-line diag-
nostics mode. To restart the module, enter Off-line Diagnostics in SMDH. When the module is
selected, an erroneous message, Station Not Responding may appear. Ignore this message and
100
select EXEC ALL. If the module passed all tests, go up a level and select RESTART. Do not pull/push
the module.
Problem Caused by Station Not Contained in any Domain

SYSMON expects all stations configured in the system to be contained in a domain. If a station is
not contained in a domain (only the letterbug and host AP name exist in the /usr/fox/sp/sldb
file), then stations that come after it in the file are not accessed correctly. This results in showing
an incorrect host AP name from SMDH’s CONFIG INFO Display.
Fault-Tolerant Troubleshooting Guide

The Fault-Tolerant Troubleshooting Guide is intended to be a service guide for some of the most
commonly encountered system problems. The suggested steps indicated for each problem cate-
gory are only recommended check procedures.
Problems that surface in many cases are faults associated with communication paths (cables, con-
nectors, internal data and power buses, and so forth). On the module level, the quickest way to
determine and correct the problem is by replacement. Spare parts are not always available, thus,
these recommended check procedures may be a practical approach.
! CAUTION
Do not attempt to repair modules in the field! Always reboot modules through Sys-
tem Management (SMDH) if possible, or by CTL/ALT/F1 for WPs.
Fault-Tolerant CP Operation, General Information

Fault tolerance in the Control Processors uses software synchronization to keep the two modules
executing exactly the same software, using exactly the same data. If the software is not synchro-
nized, synchronization is restored by the Primary module transmitting its data base to the Shadow
module in a sequence commonly referred to as a “hot remarry.” The hot remarry is essentially the
same as the initial station marriage.
NOTE
The fault-tolerant control processor marriage is broken if five hot remarries occur
within one minute. When the marriage is broken, the Shadow module is placed into
the Off-line Diagnostic Dispatcher (OLDD) state and the message “Error Escala-
tion Threshold has been exceeded” is printed on the system printer. You may
then use the System Management Displays to reboot (restart) the Shadow module
from the OLDD state.
Fault-Tolerant Pair; One Fails

If within a fault-tolerant pair of modules, one fails, the failed module’s red light (LED) turns on.
If this occurs, proceed with the following recommended check procedures. Recommended checks
need not be followed in order. If one step corrects the problem, obviously the remainder need not
be performed.
1. Make sure that the CP’s elevator connector is raised.
101
2. Assure that FBM0 is fixed using the Control Configurator under the FBM menu pick.
3. Make sure that the LAN cables are intact.
4. Make sure that the module was not put into “fault” mode from the SMDH.
5. Replace the module if all else fails. (Do not pull/push.)
CP10(s) Not Married

If the Control Processor(s) does not marry, it causes one module’s red light (LED) to turn on; and
the other module’s red and green light (LED) to turn on. If this occurs, proceed with the follow-
ing recommended check procedures. Recommended checks need not be followed in order. If one
step corrects the problem, obviously the remainder need not be performed.
1. Check the CP’s Equipment Information screen in the SMDH.
a. Verify that the equipment is configured as fault tolerant.
b. See if the CP reports as being married.
c. Verify that the EEPROM is at the current revision level. Perform an EEPROM
update, if required.
2. Verify the proper elevator position.
3. Be sure that both the top and bottom captive screws on both modules are tightly
secured.
4. Check that the fault-tolerant module connector (X-Bus) is properly installed.
5. Check the cable connections on both CPs.
6. Verify that the proper grounding procedures have been followed per the Site Planning
(B0193AB) document.
7. Reboot the suspected module using SMDH.
8. Replace the fault-tolerant module connector.
9. Replace one or both modules if all else fails.
AP20(s) Not Married

If the Application Processor 20(s) does not marry, it causes one module’s red light (LED) to turn
on and the other module’s red and green light (LED) to turn on. If this occurs, proceed with the
following recommended check procedures. Recommended checks need not be followed in order.
If one step corrects the problem, obviously the remainder need not be performed.
1. Check the AP’s Equipment Information screen in the SMDH.
b. See if the AP reports as being married.
2. Make sure that the hard disks of the two APs were identical when the procedure was
started.
secured.
102
5. Check that the double fault-tolerant module connector (X-Bus) is properly installed.
6. Check the cable connections on both APs.
7. Verify that the proper grounding procedures have been followed as described in the
document Site Planning (B0193AB).
8. Reboot the suspected module using SMDH if possible.
9. Reboot the suspected module.
10. If possible, perform an AP Shutdown for that AP, using the menu pick or by typing:
SHUTDOWN from the root level when logged into the AP at a WYSE terminal.
11. Replace the double fault-tolerant module connector.
LI(s) Not Married

If the LAN Interface(s) does not marry, it causes one module’s red light (LED) to turn on; and the
other module’s red and green light (LED) to turn on. If this occurs, proceed with the following
recommended check procedures. Recommended checks need not be followed in order. If one step
corrects the problem, obviously the remainder need not be performed.
1. Check the LI’s Equipment Information screen in the SMDH.
b. See if the LI reports as being married.
secured.
4. Check that the double fault-tolerant module connector (X-Bus) is properly installed.
5. Check the cable connections on both LIs.
6. Verify that the proper grounding procedures have been followed per the Site Planning
(B0193AB) document.
7. Reboot the suspected module using SMDH.
8. Replace the double fault-tolerant module connector.
Network Fault Detection

Following are considerations for assessing AP20 network faults.
1. If an AP20 that is currently hosting the Nodebus NFD master is “shutdown,” the
master is unable to run cable tests. However, it continues to act as the master for all
other activities. To allow cable tests to run while the AP20 is shutdown, relocate the
“cable test initiator” to the LI or another AP20 or an AP50 via SMDH
On-line Diagnostics Display.
2. The System Configurator allows 100 nodes per LAN. The system cannot support
more than 30 nodes per LAN. While configuring a system NO more than 30 nodes
per LAN should be allowed.
103
3. Token Bus Receiver and Transmitter failures are suspected failures and are reported as
such. On fault-tolerant modules the diagnostics subsystem is invoked and the sus-
pected faults are revalidated. If it is a confirmed failure then the module is failed.
4. Cable errors reported are event driven reports. If there is a double cable failure on the
Token Bus, the SMDH Display may display inconsistently or miss reporting the fail-
ure. After the failure is fixed the Carrierband Cable test should be rerun to get the lat-
est status.
5. Whenever a station is added, deleted, or moved from a System Monitor domain all
potential 802.3 (Nodebus) masters must be updated. This can be done by picking
Default Change Nodebus Master Initiator from the SMDH for an AP or LI.
Replacement of FT Modules While Both Are in Off–line

Diagnostics
Do not replace an FT shadow with a new module if both FT modules are in Off-line
Diagnostics. First restart the original primary module from SMDH. If you do not restart from
SMDH, the address information is incorrect for the original primary and you must pull/push the
module.
LAN Interface Modules

If both carrierband cables break at the same time, the token bus controller chip may lock up on
one half of a fault-tolerant pair and the LI module fails RED. If an LI fails and System Manage-
ment reports that both cables are bad, after repairing the cable system, pull/push the failed LI, or
push the Reset button on the front of the module. DO NOT RETURN IT TO FOXBORO.
For additional information, refer to the Network Cable Systems Installation and Maintenance
(B0193UW) document.
LAN Interface LEDs Red/Green and System Management Indicating

Failure
If the primary LI’s elevator is dropped, the LI LEDs are Red/Green but System Management
shows the shadow mode (after the role change) as failed. Off-line diagnostics can still be run with
the module.
(B0193UW) document.
Notes on LAN Z-Module LED Indicators

The LAN module always transmits simultaneously on both Cable A and Cable B. Therefore,
since each modem receives its own transmission, both TX LEDs and both RX LEDs are active
when a module is transmitting (see “LAN Z-Modules” on page 74 and Figure 3-1). The RX
LEDs are both active regardless of the cabling system, since reception of a modem’s own transmis-
sion occurs at the port of the module prior to the drop cable connection to a tap.
The condition described above applies to all single modules operating non-fault-tolerant, and to
the PRIMARY module of a married pair. Since the SHADOW module of a married pair does not
transmit, its RX LEDs are active only as a result of data received from the trunk cable. Therefore
the RX LEDs on a SHADOW module are an indication of the integrity of the cabling system.
104
Cabling system integrity can be further assessed by the intensity of the RX LEDs. Normally the
RX LEDs are brighter than the TX LEDs because the majority of the station’s activity is token
passing, and it receives tokens from all stations in the system, and only transmits one per token
rotation. When Cable A is broken, the intensity of the RXA LED matches that of the TXA LED
since it is not receiving from other stations on Cable A. The intensity of the RXB LED is greater
than that of the TXA, TXB LEDs if Cable B is intact.
Check LEDs are active only when unused codes are received. Since both polarities of signal are
allowed, not many codes are unused and the CHK LED rarely is active. It is not a useful indicator
of cabling system integrity. The RX LED intensity is more useful.
(B0193UW) document.
Fieldbus Module (FBM) Troubleshooting Guide

This description is intended to be a service guide for some of the most commonly encountered
system problems. The suggested steps indicated for each problem category are only recommended
check procedures.
Problems that surface in many cases are faults associated with communication paths (cables, con-
nectors, internal data, and power buses, and so forth). On the module level, the quickest way to
determine and correct the problem is by replacement. Spare parts are not always available, thus,
these recommended check procedures can be a practical approach.
! CAUTION
Do not attempt to repair modules in the field! Always reboot modules through Sys-
tem Management (SMDH) if possible, or by CTL/ALT/F1 for WPs.
FBM With or Without Expansion Module, Does Not Boot

(Red/Green LEDs On)
If the FBM with or without its expansion module does not boot, it causes the FBM’s red and
green lights (LEDs) to turn on. If this occurs, proceed with the following recommended check
procedures. Recommended checks need not be followed in order. If one step corrects the problem,
1. Make sure the FBM(s) have been fixed in the Control Configurator under the FBM
menu pick.
2. EEPROM update and download the FBM(s) from the SMDH.
For an extended Fieldbus, the flashing lights on the Fieldbus Isolator (FBI) indicate
communication during the download.
3. Remove FBM and check for bent pins.
4. Check the bus selector on the Y-adapter. The arrow should point towards the host CP.
5. Make sure the Termination Cable Assembly (TCA) type is compatible with the FBM
type. Refer to the Site Planning (B0193AB) document, Field Wiring Cross Reference
Table. TCAs for expansion modules and main FBM(s) are interchangeable only if
both modules have identical input/output functionality. They are NOT interchange-
105
able if the I/O functionality on each module is different but compatible to use.
6. Using the SMDH Equipment Change functions, run Fieldbus A and B
ENABLED/DISABLED fields to see if fieldbus conditions affect the problem.
NOTE
RUN AB PERIODIC only switches the Fieldbus at designated intervals (one hour)
providing both buses are “equally” good. The number of FBM access failures
recorded per bus determines whether switching takes place. Prior to switching, the
system checks the other bus to eliminate switching to a bad or worse bus.
7. Replace the letterbug.

8. Replace the Y-adapter.
9. Replace the FBM(s) if all else fails.
All FBMs in an Enclosure Fail, (No LEDs On)

If all the FBMs in an enclosure fail, all the lights (LEDs) turn off. If this occurs, proceed with the
following recommended check procedures. Recommended checks need not be followed in order.
If one step corrects the problem, obviously the remainder need not be performed.
1. Check for ac power loss at the junction box. Check for blown fuse (Division II config-
uration) or a tripped circuit breaker.
2. Check mounting structure bus for power to the fieldbus.
FBM Without Expansion Module Fails, (Red LED On)

If an FBM without an expansion module fails, all the lights (LEDs) turn off. If this occurs, pro-
ceed with the following recommended check procedures. Recommended checks need not be fol-
lowed in order. If one step corrects the problem, obviously the remainder need not be performed.
1. Remove FBM and check for bent pins.
3. Replace the FBM.
4. Replace the Termination Assembly.
FBM With Expansion Module Fails (Main Red/Green LEDs On;

Ext LED Red On)
If an FBM with an expansion module fails, it can cause the main FBM’s red and green lights
(LEDs) to turn on, and the extension FBM’s red light (LED) to turn on. If this occurs, proceed
with the following recommended check procedures. Recommended checks need not be followed
in order. If one step corrects the problem, obviously the remainder need not be performed.
1. Remove both FBMs. Replace the expansion module in the Mounting Structure first.
Replace the main FBM second.
2. Make sure the FBMs have been fixed in the Control Configurator under the FBM
menu pick.
3. EEPROM update and download the FBMs from the SMDH.
106
For an extended fieldbus, flashing lights on the Fieldbus Interface indicates communi-
cation during the download.
4. Check the bus selector on the Y-adapter. The arrow should point towards the host CP.
5. Make sure the Termination Cable Assembly (TCA) type is compatible with the FBM
type. Refer to the Site Planning (B0193AB) document, Field Wiring Cross Reference
Table. TCAs for expansion modules and main FBM(s) are interchangeable only if
both modules have identical input/output functionality. They are NOT interchange-
able if the I/O functionality on each module is different but compatible to use.
6. Using the SMDH Equipment Change functions, run Fieldbus A and B
ENABLED/DISABLED fields to see if fieldbus conditions affect the problem.
NOTE
RUN AB PERIODIC only switches the Fieldbus at designated intervals (one hour)
providing both buses are “equally” good. The number of FBM access failures
recorded per bus determines whether switching takes place. Prior to switching, the
system checks the other bus to eliminate switching to a bad or worse bus.
7. Remove both FBM(s) and check for bent pins.

8. Replace the letterbug.
9. Replace the Y-adapter and/or the FBM if all else fails.
FBM With Expansion Module Fails (Main Red/Green

LEDs On; Expansion LED Red Off)
If an FBM with an expansion module fails, it can cause the main FBM’s red and green lights
(LEDs) to turn on, and the expansion FBM’s red light (LED) to turn off. If this occurs, proceed
with the following recommended check procedures. Recommended checks need not be followed
in order. If one step corrects the problem, obviously the remainder need not be performed.
1. Check the Termination Assemblies:
a. Swap Termination Assemblies between the main and expansion module ONLY if
input/output functionality is identical. Keep the letterbug on the main FBM. If
still failed, swap the TCA(s) back.
b. If both modules had red and green LEDs on when the TCA(s) were interchanged,
swap them back and replace the TCA on the main FBM.
2. Remove both FBM(s) and check for bent pins.
3. Replace the expansion module.
4. Replace the main FBM.
FBM Main and Expansion Module Fail, (No LEDs On)

If the main FBM and expansion module fail, no LED(s) is on. If this occurs, proceed with the fol-
lowing recommended check procedures. Recommended checks need not be followed in order. If
one step corrects the problem, obviously the remainder need not be performed.
1. Remove the modules and check for bent pins.
107
3. Reconfigure modules for another position in mounting structure. (Possible bad con-
nector on Mounting Structure Bus). If still failed, replace the modules.
4. If after reconfiguring for other positions in the mounting structure, the module
LED(s) turn on, replace the mounting structure bus.
“No Such File or Directory

/usr/fox/sysmgm/softmgr/file/sm_lth_lc” Error Message
When performing FBM load through the message, No such file or directory
/usr/fox/sysmgm/softmgr/file/sm_lth_lc, may be seen. This message can be disregarded since
load through retries are performed.
Loss of FBM Status Messages

When the AP is heavily loaded, the AP queue size may not be large enough to handle all FBM sta-
tus messages routed to the printers. This situation can result in the loss of FBM status messages.
FBM04, FBM06, FBM44 (Redundant AO) Maintenance

Procedure
The FBM04, FBM06, or FBM44 configuration using dual transmitters and a single I/P with Ter-
mination Cable Assembly P0903SB (FBM04 or FBM44) or P0903TW (FBM06) requires peri-
odic maintenance to detect any latent faults in the individual output channels. Refer to the
“Redundant FBM Operational Considerations” in the System Equipment Installation (B0193AC)
document appendix for detailed information.
FBM05 and FBM46 Maintenance Procedure

Since the redundant connection of two FBM modules allows continuous operation even if one of
the modules fails, a periodic maintenance procedure must be performed to assure the integrity of
the modules. The purpose of this procedure is to detect any latent fault that might be masked by
the redundant module. Refer to the “Redundant FBM Operational Considerations” in the System
Equipment Installation (B0193AC) document appendix for detailed information.
Human Interface Troubleshooting Guide

The Human Interface Troubleshooting Guide is intended to be a service guide for some of the
most commonly encountered interface problems while working with a Workstation Processor.
The suggested steps indicated for each problem category are only recommended check
procedures.
WP Locks Up (Touchscreen Inoperative)

If the Workstation Processor locks up making the touchscreen inoperative, proceed with the fol-
1. Check the letterbug in the monitor.
2. Attempt to move the cursor with the keyboard, mouse, or trackball. If the other
peripherals work, cycle power on the monitor by removing and reinserting the power
cord at the rear of the monitor. (Unplugging is necessary because simply switching the
108
power switch does not remove power from some of the internal circuitry.)
3. If more than one screen is available, check the status of the touchscreen via the
SMDH.
4. Perform an EEPROM update from the SMDH.
5. Reboot the WP: perform a CTL/ALT/F1 from the WP with problems.
6. Check the bezel. Make sure it is NOT touching the touchscreen. If it is touching:
a. Adjust bezel away from the touchscreen.
b. Recalibrate the touchscreen.
7. Determine the health of the touchscreen.
a. Swap cables to another monitor, if possible.
b. If “new” monitor performs with cables from “previous” monitor, then replace orig-
inal suspect monitor.
WP Displays Frozen with Peripherals Operative

If the Workstation Processor freezes and the peripherals remain operative, proceed with the fol-
1. Check the display size:
a. Make sure the display size does not exceed the WP available memory. (Display size
+ overlay size must be less than 60 KB.) Note that the actual display size cannot be
directly ascertained.
b. If the display exceeds a certain size, the Display Configurator issues a warning
which include the display size.
c. For other displays, look at the file in its directory using the VENIX “l”
(or “ls-l”) list command. Subtract approximately 5 KB to secure overhead avail-
ability.
2. Check the overhead display:
a. Values for change “delta” may be too small, thus forcing the display to update too
frequently.
b. Increase the changed delta(s) for the display points.
3. Check if the WP may need rebooting:
a. Verify that the WP was not rebooted without subsequently rebooting the WP.
b. If this is the case, reboot the WP.
4. Verify that there are not too many trend lines on the display. The limit is three lines
extending the full width of the screen at any one time.
5. If there are too many environment picks:
a. Verify that there are not too many menu picks for this environment. The maxi-
mum is 50 for a WP10, and 100 for a WP20.
b. Count the total number of picks that could possibly be displayed if all the menus
were pulled down at the same time. Include any that do not appear at the bottom
due to the list being extended and out of view. Do not include the top menu bar
picks.
109
6. An attempt was made to call a configurator on a system with AP-switching, where the
WP was accessing the backup AP. On a normal system, only displays can be called
using the backup AP.
7. Reboot the WP.
Input/Output Data Loss on Displays

If the Processor loses input/output data on the display, and an asterisk appears in the data fields, a
white object, yellow U, and blank fields appear for other object types; then proceed with the fol-
If you suspect there is a problem in the CP:
NOTE
Peer-to-peer connections are established by the checkpoint function; thus, after
making a change in the Control Configurator, request a checkpoint or change vol-
umes, or exit the configurator.
1. Check that the compound:block.parameter truly exists.

2. Delete/undelete the block using the Control Configurator.
3. Delete/undelete the compound using the Control Configurator.
4. Checkpoint the suspect CP, upstream or downstream.
5. Contents < points to a value for which the WP was able to make a connection.
If there is a problem in the connection mechanism, recall the display. If recalling the
display several times does not cause the connection to be made, check for a correctly
specified connection.
6. If the compound is turned off, turn it on.
7. Possible problem in the Nodebus or LAN:
a. Check for hot remarries in the LAN Interface.
b. Check for loss of the Nodebus Extender.
8. Check for loss of communication between the CP and the FBM(s).
9. Check for loss of communications between the Gateway and remote device such as
the Modicon.
Touchscreen Calibration Procedure

The Touchscreen on the Workstation monitors should be calibrated periodically. To proceed,
invoke a touchscreen calibration as follows:
1. From the Software Engineer's environment, select SftMnt.
2. Select Calibrate from the pull down menu.
When performing the calibration procedure it may “timeout” if you do not touch the screen as
instructed within 20 seconds. If the timeout occurs, it is necessary to remove power from the
touchscreen controller and then restore it again.
110
The only way to remove power from the touchscreen controller is to unplug the monitor power
cord and plug it back in again. The power switch does not control power to the touchscreen con-
troller, just to the monitor.
Rebooting a WP
When rebooting a Workstation Processor, proceed with the following recommended check proce-
dures:
1. Before you reboot a WP, you should have the static display on screen. (That is, no
change-driven data coming from a control processor.) The SELECT button screen is a
static display.
2. If you have to change letterbugs, do it before you reboot. This occurs when you are
reinstalling software and use the G3BOOT letterbug.
3. After you reboot: If you changed the letterbug on a WP with peripherals (mouse,
touchscreen, keyboards), unplug the monitor power cord and plug it back in after
about ten seconds. This resets the peripheral bus so the peripherals can respond to the
new letterbug.
Keypanels, Annunciator Keyboards

A full complement of keypanels in the annunciator panel are necessary to avoid a problem with
mouse lockup. The annunciator interface PWA may interpret electrical noise as keystroke signals.
This results in occasional mouse lockup.
GCIO Firmware (Touchscreen)

Verify the station’s GCIO firmware level is 1.3. If this firmware level is at Version 1.2 or earlier an
EEPROM UPDATE should be performed from System Management. The GCIO firmware is
updated as part of the installation procedure.
Refer to the “Touchscreen Calibration Procedure” on page 110.
“smdhspf_serv IPC-1041” Error Message

The following message maybe seen after exiting SMDH and the EQUIP CHG Display has been
accessed:
smdhspf_serv IPC-1041 message could not be delivered to destination.
This message can be disregarded.
Alarm Horn Operation

ACKing the external horn does not acknowledge the System Management alarm, it only silences
the horn. To avoid this problem, the new failure must be acknowledged from SMDH to cause the
SYS button to return to solid.
Failure to Unmount Remote File Systems

System Management uses remote mounted file systems when performing Equipment Change
actions and accessing Equipment Information on stations hosted by APs other than the AP host-
ing the WP where the request originated. The remote file system is not unmounted if you return
to the System Monitors Display (the display containing all the available System Monitor
Domains) and then you close out of System Management, after performing Equipment Change
111
actions or accessing Equipment Information on stations hosted by a remote AP. Closing out of
System Management at any lower display level properly removes the mount of the remote file sys-
tem.
If a not understood rmount exists after exiting System Management, possibly because of not exit-
ing System Management properly as previously stated, the following steps unmounts the remotely
mounted file system:
1. Enter System Management on a WP hosted by the AP with the remote file system
mounted.
2. Select a Station hosted by the AP with the remote file system mounted.
3. Enter the Equipment Change or Equipment Information for the selected station.
(This unmounts the remote file system.)
4. Exit System Management using CLOSE.
Printer Troubleshooting Guide

The Printer Troubleshooting Guide is intended to be a service guide for some of the most com-
monly encountered printer problems. The suggested steps indicated for each problem category are
only recommended check procedures. Additionally, some of the commonly used networked
printer commands from the Solaris SunOS document Setting Up User Accounts, Printers and Mail
are included here.
Buffer Full – No Output on Printer

If the printer buffer suddenly becomes full, and results in no output on the printer, proceed with
the following recommended check procedures. Recommended checks need not be followed in
order.
1. Disable the printer locally via the SELECT button. (If you want to “fail” the printer,
turn off the power).
2. Check if the printer may be out of paper.
3. Check if there is a paper jam. Check paper path.
4. The system is not backing up properly:
a. A Device Monitor should be configured on only one AP on the network, and the
DM software should be present on that AP.
b. The path to the AP with the DM should be healthy.
5. Check backup printer characteristics:
a. Must use the same protocol (XON/XOFF or READY/BUSY) as the main printer.
b. Should be of a similar type.
6. Evaluate error condition protocols:
a. If the system does not fail the printer when a condition exists which prevents
printing, then the buffers in the printer, COMM10, AP, or WP may be filled up.
This effectively hangs up the AP or WP.
b. Foxboro documentation directs you to set up printers to indicate certain condi-
tions by use of the XON/XOFF protocol. This causes the printer to fail if,
112
for example, the power is turned off on the printer, but not if the SELECT button is
pushed.
c. READY/BUSY protocol can be used instead of XON/XOFF.
d. Table 3-4 summarizes the two modes:
Table 3-4. Printer Modes – XON/XOFF and Ready/Busy
XON/XOFF Ready/Busy
Printer buffer full No Failed
Power Off Failed Failed
“SELECT” Off No Failed
7. Disk may have filled up. See below.
AP Disk Full – Printer Files

If the Application Processor disk suddenly becomes full, and results in no output on the printer,
proceed with the following recommended check procedures. Recommended checks need not be
followed in order. If one step corrects the problem, obviously the remainder need not be per-
formed.
1. The printer buffer may be full:
See “Buffer Full – No Output on Printer” on page 112.
2. Spooling to a bad device:
a. If there are any spooled files waiting for a nonexistent device, cancel them.
b. The default spooling device should be an existing and healthy device. If it is not,
the print requests sent to the default device remain and use up disk space. It is
common to find the default device is lp1.
c. On a Personal Workstation, lp1 is the local parallel or serial port. An AP has no
lp1, however, the default spooling device can be changed by typing the following:
/usr/lib/lpadmin -dLP01 (using whichever printer name desired instead of
LP01).
NOTE
There is no need to stop the lp scheduler when performing this function.
Determining Printer Status

Use the lpstat command to find out about the status of the LP print service. You can check on
the status of your own jobs in the print queue, determine which printers are available for you to
use, or determine request ids of your jobs if you want to cancel them. Execute each of the follow-
ing commands by pressing the Return key.
Checking on the Status of Your Print Requests

Enter the following command to find out the status of your own spooled print requests:
$ lpstat
113
A list of the files that you have submitted for printing is displayed.
In the following example, on the system AP5001:, one file is queued for printing to the printer
lp01:
$ lpstat
lp01-10Fred1261 Mar 12 17:34 on AP5001:
The lpstat command displays one line for each print job, showing the request ID, followed by
the user who spooled the request, the output size in bytes, and the date and time of the request.
Checking on Available Printers

To find out which printers are configured on your system, type the following:
$ lpstat -s
The status of the scheduler is displayed followed by the default destination and a list of the sys-
tems and printers that are available to you.
In the following example, on the system AP5013:, the scheduler is running, the default printer is
lp01, and two network printers, lp01 and lp02 are available:
$ lpstat -s
scheduler is running
system default destination: lp01
system for lp01: AP5001:
system of lp02: AP5010
$
Displaying All Status Information

The -t option for lpstat gives you a short listing of the status of the LP print service.
To display a short listing of all status information, type the following:
$ lpstat -t
All available status information is displayed.
In the following example, there are no jobs in the print queue. When files are spooled for print-
ing, the status of those print requests is also displayed.
$ lpstat -t
scheduler is running
system default destination: lp01
system for lp02: AP5010:
lp01 accepting requests since Wed Jan 2 18:20:10 PST 1991
lp02 accepting requests since Mon Mar 4 15:53:47 PST 1991
printer lp01 is idle. enabled since Wed Jan 2 18:20:22 PST 1991. avail-
able.
Printer lp02 is idle. enabled since Mon Mar 4 15:53:44 PST 1991.
available.
$
Displaying Status for Printers

You can request printer status information for individual printers using the -p option to lpstat.
The option shows whether the printer is active or idle, when it was enabled or disabled, and
whether it is available to accept print requests.
To request status for all printers on a system, type the following:
$ lpstat -p
114
In the following example, two printers are idle, enabled, and available. If one of those printers has
jobs in the print queue, those jobs are displayed.
$ lpstat -p
printer lp01 is idle. enabled since Wed Jan 2 18:20:22 PST 1991. available.
printer lp02 is idle. enabled since Mon Mar 4 15:53:44 PST 1991. available.
$
To request status for an individual printer by name, type the following:
$ lpstat-p printername
Where printername is the name of the specific printer.
Summary Table of lpstat Options

You can request different types of printing status information using the lpstat command and ter-
minating the command line by pressing the Return key. Table 3-5 summarizes the frequently-
used options for the lpstat command. Use these options individually, or combine them in any
order on the command line. When you combine options, use a space between each option and
repeat the dash (-).
For example, to show a long list of status for an individual printer, you enter the following:
$ lpstat -p printername -1
Where printername is the name of the printer for which you want to view status.
Table 3-5. Summary of Frequently Used lpstat Options
Option Description
-a Accept. Show whether print destinations are accepting requests.
-c Class. Show classes and their members.
-d Destination. Show default destination.
-f Forms. Show forms.
-o Output. Show status of output.
-p (list) (-D) (-1) Printer/Description/Long list. Show status of printers.
-r Request. Request scheduler status.
-R Show position of job in the sequence.
-s Status. Show status summary.
-S Sets. Show character sets.
-u (username) User. Show requests by user.
-v Show devices.
Canceling a Print Request

Use the cancel command to cancel a print request while it is in the queue or while it is printing.
Terminate the command line by pressing the Return key. To cancel a request, you need to know
its request ID. The request ID always includes the name of the printer, a dash, and the number of
the print request. When you submit the print request, the request ID is displayed. If you do not
remember your request ID, type lpstat and press Return. Only the user who submitted the
request, or someone logged in as root or lp can cancel a print request.
115
Canceling a Print Request by ID Number

To cancel a print request, type the following:
$ cancel requestid
Where requestid is the request ID number of the desired print request.
A message is displayed telling you that the request is canceled. The next job in the queue begins
printing.
In the following example, two print requests are canceled:
$ cancel lp01-3 lp01-4
request “lp01-3” cancelled
$
Canceling a Print Request by Printer Name

You can also cancel just the job that is currently printing (if you submitted it) by typing the
printer name in place of the request ID as follows:
$ cancel printername
Where printername is the name of the printer to which you sent the request.
A message is displayed telling you that the request is canceled. The next job in the queue begins
printing.
In the following example, the current printing request has been canceled.
$ cancel lp01
$
Your system administrator can log in as root or lp and cancel the currently-printing request using
the printer name as the argument for the cancel command.
Accepting/Rejecting Print Requests

To perform these tasks, you must become root or lp.
Accepting Print Requests

To set a printer to accept print requests:
Type:
accept printer -or- class-names and press Return.
The printer (or class of printer) begins accepting print requests. You can specify several printers or
classes by listing the printer names, and separating the names with a space. If you want a print
server to accept print requests from a print client, run the accept command on both the print cli-
ent and the print server.
lp01 # accept lp01
destination “lp01” now accepting requests
Rejecting Print Requests

To set a printer to reject (stop accepting) print requests:
♦ Type reject -r “reason” printer- or class-names and press Return.
116
The printer (or class of printer) stops accepting new requests. You can specify several
printers or classes by listing the printer names, and separating the names with a space.
The queued requests continue printing as long as a printer is enabled. You can omit -r
and the reason for rejecting print requests if you do not want to specify a reason. You
can reject print requests for all users of a printer by typing the reject command on
the print server. Alternatively, you can reject print requests for a specific print client or
group of print clients by typing the reject command on each of the print clients.
AP5001:# reject -r “lp01 is down for repairs” lp01
destination “lp01” will no longer accept requests
Enabling/Disabling a Printer
To perform these tasks you must become root or lp.
Enabling a Printer
To Enable a Printer:
♦ Type enable printer-names and press Return.
The printer begins processing queued requests. You can list several printer names, sep-
arating the names with a space. If you want a print server to process files from a print
client, run the enable command on both the print client and the print server.
AP5001:# enable lp01
printer “lp01” enabled.
NOTE
You can enable or disable individual printers, not classes of printers.
Disabling a Printer
To disable a printer:
♦ Type disable (option) printer-names and press the Return key.
The printer stops processing queued requests. You can list several printer names sepa-
rating the names with a space. If you want a print client to stop sending requests to a
print server, run the disable command (without -c or -w) on the print client.
Use the following table to choose an option.
Table 3-6. Options to the Disable Command
Option Description
none Disable the printer, saving the current job for reprinting when the
printer is re-enabled.
-c Cancel the current job, then disable the printer. The current job is not
printed later.
-w Wait until the current job is finished before disabling the printer.
-r “reason” Provide users with a reason the printer is disabled. The reason is stored
and displayed whenever a user checks on the status of the printer
(lpstat -p).
117
For example, suppose you want to stop the current job, and save it to print later, and give a reason
the printer is disabled.
AP5001:# disable -r “changing the form” lp01
AP5001:# lpstat -p lp01
printer lp01 disabled since Mon Mar 2 12:11:31 EST 1992.
available.
Changing the form
AP5001:#
NOTE
You cannot enable or disable classes of printers. Only individual printers can be
enabled or disabled.
The enable and disable commands, by default, are owned by lp, and may only be run by lp or
root.
To disconnect a print client from a print server:
♦ On the print client, type:
disable printer-name -r “comment” and press Return.
The transfer of files from the print client to the print server is stopped. The printer
can still serve other clients. The -W and -c options do not apply.
AP5013: # disable lp01 -r “lp01 is down for repairs”
printer “lp01” disabled.
Starting/Stopping the Print Service Scheduler

Starting the Print Service Scheduler
To start the print service scheduler:
1. Become root or lp.
2. (Optional) Type lpstat -r and press Return.
You may want to check if the scheduler needs to be started. If the scheduler is not run-
ning, the message scheduler is not running is displayed.
3. Type /usr/lib/lp/lpsched and press Return.
AP5013: # /usr/lib/lp/lpsched
Print services started.
4. If the scheduler does not start:
a. Type ls/var/spool/lp and press Return.
AP5013:# ls
SCHEDLOCK bin logs requests temp
admins fifos model system tmp
AP5013:#
b. If a SCHEDLOCK file is listed, type rm /var/spool/lp/SCHEDLOCK and press Return.
The SCHEDLOCK file is removed. The file /var/spool/lp/SCHEDLOCK is created
when the scheduler starts, to make sure that only one copy of lpsched is running.
The lpshut command automatically removes the SCHEDLOCK file. If lpsched is
118
stopped in any other way, you must remove the SCHEDLOCK file before you can
restart lpsched.
c. Type /usr/lib/lp/lpsched and press Return.
The print service scheduler should start. If the message Print services started
does not appear, check the lpsched log in the /var/lp/logs directory for error
messages that may explain the problem and point to a solution.
5. If the scheduler appears to start but does not start:
You may get the message Print services started but lpstat -r says the scheduler
is not running and its process does not show up with the ps command. Additionally,
error messages appear whenever you try to use any lp command.
a. Check the lpsched log in the /var/lp/logs directory for error messages that may
explain the problem and point to a solution.
b. If there is no apparent error, look for recent files, such as logs, that the scheduler
may be getting stuck on.
While the scheduler is starting up, it checks many of the directories and files it
uses or creates during normal operation. If there is a problem with one of the files,
it can prevent the scheduler from completing its initialization. You may need to
remove files recently created by the LP print service, such as those in
/var/spool/lp/logs.
! CAUTION
The next step is a last resort. Be very careful not to delete files critical to the opera-
tion of the LP print service, such as the configuration files in /etc/lp.
c. Delete files that appear troublesome, but you should first copy them to other file
names.
d. Type /usr/lib/lp/lpsched and press Return. The scheduler should start.
Stopping the Print Service Scheduler

To stop the print scheduler:
1. (Optional) Type lpstat -r and press Return.
You may want to check if the scheduler needs to be stopped. When the scheduler is
running, the message scheduler is running is displayed.
2. Type lpshut and press Return.
AP5013:# lpshut
print services stopped.
3. If the scheduler does not stop:
a. Type ls /var/spool/lp and press Return.
AP5013:# ls /var/spool/lp
SCHEDLOCK binlogsrequeststemp
admins fifosmodelsystemtmp
AP5013:#
b. If a SCHEDLOCK file is not listed, type:
119
cd /var/spool/lp;touch SCHEDLOCK; chown lp SCHEDLOCK;

chmod 664 SCHEDLOCK
and press Return.
The SCHEDLOCK file is created. This file is normally created when the scheduler
starts, to make sure that only one copy of lpsched is running. The lpshut com-
mand automatically removes the SCHEDLOCK file. If the file is removed in any other
way, you must recreate the SCHEDLOCK file before you can stop lpsched.
c. Type lpshut and press Return. The print scheduler is stopped.
AP50 with Printer

1. When an AP50 with an attached printer is rebooted, the printer head oscillates during
the memory diagnostic test. This is normal. Additionally, the printer output is illegi-
ble during various stages of the boot sequence. This does not indicate a boot sequence
failure. A message confirming successful completion of a AP50 boot sequence is
printed on the printer.
2. If an AP50 printer fails, the printer output is redirected to the backup printer. After
the AP50 printer is fixed, it must be put on-line from the SMDH Display in order to
direct output to the main printer. (Rebooting of AP50 shows the printer on-line on
the SMDH Display but printer queuing is disabled.)
Printing a Header Page with lp

The AP50 lp command, by default, does not print a header page (for example, with date, file-
name, and so forth). A header can be printed by issuing the following command from the AP50:
pr | lp -d LPxx <filename> # LPxx represents the destination printer.
Print Device Failure After Alarm “Burst” Condition

To handle a large burst of alarm messages the CMP10 has been changed to allow for backed-up
messages to be rerouted to a remote backup print device. When the primary print device is in the
rerouting mode the status of the print device is “OFF-LINE” “NOT FAILED” in the SMDH
Display. Once the burst condition has subsided, to return the primary to “ON-LINE” “NOT
FAILED” you must manually toggle the print device off-/on-line or power reset the print device.
Multiple Printscreen Requests Caution

Multiple printscreen requests can exhaust memory resources in the CMP10/15. This can cause
other devices to be marked “OFF-LINE” “NOT FAILED” in SMDH. To recover, the devices
must be manually deselected/selected or powered off/on. Single synchronous printscreen requests
avoids this situation.
Nodebus Troubleshooting Guide

The Nodebus Troubleshooting Guide is intended to be a service guide for some of the most com-
monly encountered nodebus problems. The suggested steps indicated for each problem category
are only recommended check procedures.
120
Reattaching a Nodebus
If the Nodebus becomes isolated from the rest of the I/A Series network for any amount of time,
proceed with the following recommended check procedure.
1. This condition may be due to Carrierband LAN Interface maintenance. If so, manu-
ally invoke an attachment program after that Nodebus is physically reattached to the
network.
a. In to VT100 mode, type:
/usr/fox/bin/tools/attch_ssb
This program must be run on all AP(s) that host system Monitor processes. It allows
the SYSMON to reestablish communication with the WP SYS button(s) it reports to.
The program completes in only one to two seconds, then exits. It does not need to be
run in the background.
Fiber Optic Nodebus Extension Troubleshooting

Guide
Perform the following steps:
1. Check the status of the MODULE STATUS LEDs (Red and Green LEDs located
below the Letterbug). A red LED indicates a clock, module, optical power, or other
fault. A green LED (only) indicates sufficient clock or power. If both red and green are
on, replace the module. If the red LED is on, the LINK MON LED can not be on.
2. Check the integrity of the Letterbugs – that the right letter (A or B) is installed in the
appropriate (right-most) position.
3. Check the status of the FONBE module LINK MON LED at each end of the failed
link. This LED should always be on even with no transmission activity. If the LINK
MON LED is off, it is likely that:
♦ The fiber optic connections to this or the other module are bad
♦ The transmit cables are crossed or interconnected
♦ The FONBE module at the other end of the link is bad or not powered.
An open fiber line does not corrupt the Nodebus on either end of the link. Transmis-
sion is inhibited while the LINK LED is inactive.
NOTE
Investigate the System Maintenance Level. Fiber optic and copper cable faults
should be the same.
Diskette Drives and SCSI Controller for the AP20

Problem: the SMS SCSI to diskette controller malfunctions or “freezes” the SCSI bus so that no
other SCSI activity can take place.
Solution: Replacement of the SMS SCSI controller with the TEAC Diskette controller.
121
1. Starting with the Software Release 2.2.1, support is maintained for both the TEAC
Diskette controller and SMS SCSI controller.
Software releases prior to 2.2.1 do not have TEAC SCSI support, only SMS SCSI
support. This prior software does not work properly when the TEAC SCSI device is
installed.
2. For customers using software prior to 2.2.1, The Foxboro Company maintains a sup-
ply of SMS Diskette controllers for the following applications:
♦ Dual Diskette P Adapters, P0400QL
♦ Wedge applications with disk drives(s), P0900DY
3. The new TEAC Diskette controllers can be identified by the following assemblies:
♦ Dual Diskette P Adapters, P0900CW
♦ Wedge applications with disk drives(s), P0911HT
Jumper settings for the new version disk drive and controller can be found in the installa-
tion document.
Sony 20-Inch Display (with or without Touchscreen)

With use, the picture brightness of any cathode ray tube gradually deteriorates over time.
The Sony 20-inch display can be rejuvenated a maximum of three times. The rejuvenation pro-
cess requires special tools and is performed by Foxboro personnel. Consult your Foxboro cus-
tomer service representative for further information.
FBM Memory Parity Error Rates for I/A Series

Stations
The Foxboro Company has calculated the memory parity error rate for each type of I/A Series sta-
tion. The rates are based upon information from the suppliers of the DRAM (dynamic random
access memory) and SRAM (static random access memory). The I/A Series stations should oper-
ate at the MTBF (mean time between failure) rates listed in Table 3-7.
Table 3-7. Parity Error Rates for I/A Series Stations
Soft Parity Error Rate Hard Parity Error Rate

Station Module Type (MTBF in Years) (MTBF in Years)
50 Series 2 5
AP20 4 10
AP10, CP10, COM10, LAN, 9 20
SSG, WP10, WP20
COM15 (Gateways) 9 20
CP30, CP40, GW30 4 10
(Integrator 30), WP30
FBMs Not Applicable 900
122
Conditions that can increase the soft memory parity error rate are externally introduced electrical
noise, and/or an extreme temperature. If soft errors occur in an I/A Series station module at a rate
higher than the MTBF rate listed in the table above for that station type, check the system for
noise and temperature extremes. This action is especially important if soft errors occur with more
than one module in the system.
Module Replacement Policy for Hard Parity Error Failures

If a hard parity error occurs in I/A Series system, the module fails (red LED state). Return the
module to The Foxboro Company for repair.
If a soft parity error occurs, the module automatically reboots to clear the error, and continues
operation. Keep the module in service unless the soft error rate exceeds the MTBF listed in
Table 3-7. Replace the module only if the MTBF rate is excessive, and the error rate is not a result
of noise and temperature factors.
123
124
Index
120 MB disk drive 4, 5
A
Adapter, Y 105, 106, 107
Air filter
120 MB hard disk drive 4
Alarm horn operation 111
Allen-Bradley
peripheral information, fault location table 61, 62
PLC-5 series fault location table 66
redundant ECB information, fault location tables 63
station, fault location table 64
Annunciator keyboards 111
AP20
data storage device replacement 89
AP50 with printer 120
Application layer counters 33
Application processor 20
diagnostic tests 20
not rebooting 97
Asterisk in data field 110
B
Battery backup power 59
Battery care
IPM06, IPM06A, and IPM06D 80
C
Calibration
touchscreen 110
Canceling a print request 115
Carrierband LAN interface
diagnostic tests 23
Cleaning
120 MB hard disk drive 4
data storage devices 4
keyboards 3
mouse (except optical mouse) 3
printers 3
trackball 5
Close button 112
Control processor 10, 30, and 40
125
B0193AD – Rev R Index
diagnostic tests 19
Corrective maintenance 73
Counters
application layer 33
MAC sublayer 30
network layer counters, LI only 35
network layer, LI only 35
peripheral 36
station loading 35
system event, explanation of 29
transport layer 31
CP30/40
uploads 99
D
Device integrator 30 18
Diagnostic tests
application processor 20 20
carrierband LAN interface 23
control processor 10, 30, and 40 19
INTERSPEC integrator 25
processor 15/30, INIs, and gateway 18
SPECTRUM slave gateway 21
workstation processor 30 21
Diagnostics
nonreportable 7
reportable 7
startup 7
Disable
printer 117
uploads 100
Display field
top menu 9, 109
Displays
station status 36
Domain
station not contained in 101
DRAM failures 72
E
Earthing
green wire 89
EEPROM
revision level 102
update 106
Electrical noise 111
Electrical power requirements
fan power 92
126
Index B0193AD – Rev R
Enable printer 117

Enclosures
preventive maintenance 1
Error message
“No Such File or Directory /usr/fox/sysmgm/softmgr/file/sm_lth_lc” 108
“smdhspf_serv IPC-1041” 111
Event counters 25
Exit button 15, 110, 112
Expansion LED red off 107
Ext LED red on 106
F
Failure
AP disk full – printer files 113
AP20(s) not married 102
buffer full – no output on printer 112
CP10(s) not married 102
fault-tolerant pair, one fails 101
FBM
main and expansion module fails (no LEDs on) 107
with expansion module fails (main red/green LEDs on 107
with or without expansion module, does not boot (red/green LEDs on) 105
without expansion module (main red/green LEDs on 106
without expansion module (red LED on) 106
general module 98
input/output data loss on displays 110
LAN interface LEDs red/green and system management indicating failed 104
LI(s) not married 103
loss of FBM status messages 108
nodebus extender 98
print device failure after alarm “burst” condition 120
to unmount remote file systems 111
WP displays frozen, (peripherals operative) 109
WP locks up, (touchscreen inoperative) 108
Fan and grill assembly replacement 85
Fan power 92
Fault analysis xiii, 7
fault location tables 8
startup diagnostics 7
station fault tests 8
station performance tests 8
tasks 8
Fault detection
network 103
Fault location table 8, 38, 61, 62
A-B PLC-5 66
Allen-Bradley peripheral information 61, 62
Allen-Bradley redundant ECB 63
Allen-Bradley station 64
127
FD gateway peripheral information 55

intelligent field device information 48
INTERSPEC AIM peripheral information 57
INTERSPEC integrator translator information 56
INTERSPEC UIO peripheral information 59
peripheral printer/terminal information 70
station equipment information 43
WP50/WP51 peripheral information 68
Fault-tolerant module connector
installation 90, 91
Fault-tolerant troubleshooting guide 101
FBM
parity errors 72, 122
redundant outputs maintenance 108
FBP10 fault information 46
FBP11-FBP14 fault information 46
FD gateway peripheral information, fault location table 55
Fiber optic nodebus extension troubleshooting guide 121
Fieldbus
Y adapter 105, 106, 107
Fieldbus cluster I/O fault information 46
Fieldbus module
startup diagnostics 8
troubleshooting guide 105
Front-mounted fault-tolerant module connector
installation 91
G
GCIO firmware 111
General module failure 98
H
Heading page
printing with lp 120
Human interface troubleshooting guide 108
I
I/A Series FBM response to memory parity errors 72
I/A Series maintenance philosophy xiii
I/O Static discrete submodule replacement 79
Icon, action 27
IE16 fan power 92
IE32 fan power 92
INI 10 information, fault location table 67
Input power bus
pin assignments 92
Input power modules
input wiring configuration 93
128
Input wiring configuration for input power modules 93

Intelligent field device information, fault location table 48
INTERSPEC
integrator translator information, fault location table 56
INTERSPEC AIM peripheral information, fault location table 57
INTERSPEC integrator
diagnostic tests 25
INTERSPEC UIO peripheral information, fault location table 59
IPM06, IPM06A, and IPM06D battery care 80
IPM06, IPM06A, and IPM06D modules
normal maintenance 81
reinstallation 82
IPM7, 8, 9 fan power module replacement 84
J
Junction box circuit breaker replacement 87
K
Keypanels 111
L
LAN interface LEDs red/green and system management indicating failed 104
Letterbug replacement 88
Local nodebus 9, 15
Lock up
bus controller chip 104
WP locks up, (touchscreen inoperative) 108, 109, 110
lpstat options
summary, table of 115
M
MAC sublayer counter 30
Magnetic tape drive
preventive maintenance 5
Maintenance philosophy
I/A Series xiii
Memory parity errors 71, 72, 122
Module
replacement policy (parity errors) 123
status indicators 73
Y 105, 106, 107
Modules
hosted by an AP not rebooting 97
Mounting structure bus replacement 89
Mouse
cleaning 3
Multiple printscreen requests caution 120
129
N
Network
fault detection 103
Network layer counter, LI only 35
Network layer counters, LI only 35
Nodebus
local 9, 15
reattaching 121
Nodebus extender failure 98
Nodebus troubleshooting guide 120
Nonreportable diagnostics 7
Not rebooting
AP boots, one or more stations 97
application processor 20 97
modules hosted by an AP 97
single module 96
Notifying Foxboro of uploads 100
O
Operator procedures for fault analysis tasks 8
P
Parity errors 72
hard and soft 72
rates 122
Performance tests
station 25
Peripheral
counters 25, 36
FBP10 fault information 46
FBP11 through FBP14 fault information 46
interface startup diagnostics 8
printer/terminal information, fault location table 70
Pin assignments for the input power bus 92
Preventive maintenance xiii, 1
enclosures 1
keyboards 3
MIWs 2
modular industrial workstations 2
monitor-based peripherals 2
mouse 3
mouse (except optical mouse) 3
printers 3
TapePort magnetic tape drive 5
trackballs 5
Print requests
canceling 115
Printer
130
enabling or disabling 117

print device failure after alarm “burst” condition 120
start or stop the print service scheduler 118
status, determining 113
with AP50 120
Printers
cleaning 3
Printing
heading page with lp 120
Processor 15/30, INIs, and gateway
diagnostic tests 18
Processor module
R
Rear-mounted fault-tolerant module connector
installation 90
Reattaching a Nodebus 121
Rebooting a WP 111
Red/green state, module 100
Redundant outputs (maintenance) 108
Replacement
AP20 data storage device 89
fan and grill assembly 85
FT modules while both are in off-line diagnostics 104
I/O static discrete submodule 79
IPM7, 8, 9 fan power module 84
junction box circuit breaker 87
letterbug 88
mounting structure bus 89
Reportable diagnostics 7
Revision information xiii
S
Schedlock file 118
Screen format
top menu 9, 109
Service scheduler, starting or stopping 118
Single module not rebooting 96
SMDH equipment change functions 107
Sony 19-inch display
rejuvenation 122
Sony 20-inch display
deterioration 122
SPECTRUM control integrator fault information 46
SPECTRUM slave gateway 21, 22
Startup diagnostic tests
fieldbus module 8
131
peripheral interface 8
system station 7
Startup diagnostics 7
Station
equipment information, fault location table 43
fault tests 8
loading counters 35
not contained in any domain 101
performance tests 8, 25
status displays 36
uploads 98
Status displays 36
System
event counters, explanation of 29
management counters 25
station kernel diagnostics 7
System event counters
network layer, LI only 35
System Management Display Handler (SMDH) 38
System power configurations
battery backup 59
T
Tables, fault location 38
TapePort preventive maintenance 5
Terminal emulation 99, 100, 121
Termination cable assembly (TCA) 107
Tests, diagnostic startup 7
Top menu bar 9, 109
Touchscreen 111
calibration procedure 110
Transport layer counters 31
Troubleshooting
fault-tolerant 101
fiber optic nodebus extension troubleshooting guide 121
fieldbus module 105
human interface guide 108
nodebus guide 120
printer 112
processor modules troubleshooting guide 96
U
Uploads
CP30/40 99
disabling 100
notifying Foxboro 100
station 98
WP30 99
132
V
VT100 mode 99, 100, 121
W
Workstation processor 30
diagnostic tests 21
WP rebooting 111
WP3
uploads 99
WP50/WP51 peripheral information, fault location table 68
Y
Y-adapter 105, 106, 107
133
33 Commercial Street
Foxboro, Massachusetts 02035-2099
United States of America
www.foxboro.com
Inside U.S.: 1-866-746-6477
Outside U.S.: 1-508-549-2424 or contact your local Foxboro representative.
Facsimile: 1-508-549-4999
Printed in U.S.A. 1104

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B0193AD

Copyright 1990-2004 Invensys Systems, Inc.

1. Preventive Maintenance .................................................................................................... 1

2. Fault Analysis .................................................................................................................... 7

Communication Processor 15/30, INIs, and Gateways .................................................. 18

FBM Replacement using the Output Bypass Station .......................................................... 77

CP10(s) Not Married ....................................................................................................... 102

Enabling a Printer ........................................................................................................ 117

Index .................................................................................................................................. 125

2-36. Equipment Information Display for Printer/Terminal ................................................ 71

Site Planning – B0193AB

Hazardous Location Precautions (CSA Requirements)

Where replacement of a component could ignite the explosive atmosphere:

Industrial Enclosures 16/32 – Air Filters

Metal Enclosures (Vented) – Air Filters

Modular Industrial Workstations

Monitor-Based Peripheral Devices

Data Storage Devices

120 MB Hard Disk Drive – Air Filter

Pinch bezel with

Wangtek TapePort Drive

Table 1-1. TapePort Tape Drive Recommended Preventive Maintenance Schedule

Item Interval (or as required)

Drive Capstan Cleaning

Perform the following steps to clean the capstan:

Startup Diagnostic Tests

Table 2-1. FBM Startup Diagnostics

CHI Checksum Tests the EEPROM used for code memory.

Table 2-2. Peripheral Interface Startup Diagnostics

CHI Checksum Tests the EEPROM used for code memory.

Operator Procedures for Fault Analysis Tasks

Carrierband LAN Display Access

Nodebus Display Access

Figure 2-1. Carrierband LAN Display

Figure 2-2. Nodebus Display

Figure 2-3. Carrierband LAN On-line Diagnostics Display

Figure 2-4. Nodebus On-line Diagnostics Display

PIO Bus Display Access

Figure 2-5. PIO Bus Display

Nodebus Cable Test Loopback Message Reporting

1. A loopback request is sent on Cable A requesting a response on Cable A.

Table 2-3. Cable Faults Truth Table

Message Paths Conclusions

The test status results are:

Figure 2-6. Off-line Diagnostics Display, Typical

Station Diagnostic Tests

Communication Processor 10 and 760/761 Gateway

Table 2-4. Communication Processor 10 and 760/761 Gateway Diagnostics

Communication Processor 15/30, INIs, and Gateways

♦ SPECTRUM Master Gateway – Non-Redundant (SIP-R)

Table 2-5. Communication Processor 15/30, INIs, and Gateways Diagnostics

Control Processor 10, 30, and 40

Table 2-6. Control Processor Diagnostics

8087 TEST Verifies mathematical functions of 8087.

Figure 2-8. Off-line Diagnostics, Control Processors 10, 30, and 40

Table 2-7. AP20 Diagnostics

Figure 2-9. Off-line Diagnostics, Application Processor 20

Table 2-8. WP30 Diagnostics