Honeywell Hpm Assembly instructions

TotalPlant Solution (TPS) System

HPM

High-Performance Process Manager

Service

HP13

R688

December 2020

Release R688

ii HPM High-Performance Process Manager Service R688

Honeywell December 2020

Notices and Trademarks

Release R688 December 2020

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied

warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may

be stated in its written agreement with and for its customers.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and

specifications in this document are subject to change without notice.

Honeywell, PlantScape, Experion PKS, and TotalPlant are registered trademarks of Honeywell International Inc.

Other brand or product names are trademarks of their respective owners.

Honeywell Process Solutions

1860 W. Rose Garden Lane

Phoenix, AZ 85027 USA

1-800 822-7673

R688 HPM High-Performance Process Manager Service iii

December 2020 Honeywell

About This Document

This document provides instructions for servicing the High-Performance Process Manager (HPM). The

instructions consist of fault isolation and removal/replacement procedures at the Optimum Replaceable Unit

(ORU) parts level.

ATTENTION

With TPN R684, Enhanced Universal Control Network (EUCN) is introduced.

In EUCN, the traditional coaxial cable system is no longer utilized and is

replaced with a Fault Tolerant Ethernet (FTE) based communication network.

Throughout the document, unless specifically mentioned, the terms HPM,

NIM, and UCN are interchangeably used with the terms EHPM, ENIM, and

EUCN respectively.

ATTENTION

With TPN R686, the Enhanced Network Bridge (ENB) is introduced. The

ENB is a variant of the NIM that allows communication between the LCN and

both UCN and EUCN networks. It can communicate over coaxial-based UCN

and FTE-based EUCN communication networks and provides a gateway

function between the UCN and the EUCN. The ENB also facilitates on-

process migration from HPM to EHPM (assuming you have redundant

HPMs).

ATTENTION

Beginning with TPN R686, Fieldbus support is withdrawn.

Release Information

Document Name

Document ID

Release

Number

Publication

Date

High-Performance Process Manager Service -

HP13

R688

December

2020

Document Category

Troubleshooting and Maintenance

References

iv HPM High-Performance Process Manager Service R688

Honeywell December 2020

References

The following list identifies all documents that may be sources of reference for material discussed in this

publication.

Document Title

HPM Specification and Technical Data

HP03-600

HPM Planning

HP02-600

HPM Installation

HP20-600

HPM Checkout

HP20-510

PM I/O Installation (PM/APM/HPM)

PM20-620

Support and Other Contacts

R688 HPM High-Performance Process Manager Service v

December 2020 Honeywell

Support and Other Contacts

For support, contact your local Honeywell Process Solutions Customer Contact Center (CCC). To find your local

CCC visit the website, https://www.honeywellprocess.com/en-US/contact-us/customer-support-

contacts/Pages/default.aspx.

Symbol Definitions

vi HPM High-Performance Process Manager Service R688

Honeywell December 2020

Symbol Definitions

The following table lists those symbols used in this document to denote certain conditions.

Symbol

Definition

ATTENTION: Identifies information that requires special

consideration.

TIP: Identifies advice or hints for the user, often in terms of

performing a task.

REFERENCE -EXTERNAL: Identifies an additional source of

information outside of the bookset.

REFERENCE - INTERNAL: Identifies an additional source of

information within the bookset.

CAUTION

Indicates a situation which, if not avoided, may result in equipment

or work (data) on the system being damaged or lost, or may result in

the inability to properly operate the process.

CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also be used

to alert against unsafe practices.

CAUTION symbol on the equipment refers the user to the product

manual for additional information. The symbol appears next to

required information in the manual.

WARNING: Indicates a potentially hazardous situation, which, if not

avoided, could result in serious injury or death.

WARNING symbol on the equipment refers the user to the product

manual for additional information. The symbol appears next to

required information in the manual.

WARNING, Risk of electrical shock: Potential shock hazard where

HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or

60 VDC may be accessible.

ESD HAZARD: Danger of an electro-static discharge to which

equipment may be sensitive. Observe precautions for handling

electrostatic sensitive devices.

Protective Earth (PE) terminal: Provided for connection of the

protective earth (green or green/yellow) supply system conductor.

Functional earth terminal: Used for non-safety purposes such as

noise immunity improvement. NOTE: This connection shall be

bonded to Protective Earth at the source of supply in accordance

with national local electrical code requirements.

Symbol Definitions

R688 HPM High-Performance Process Manager Service vii

December 2020 Honeywell

Symbol

Definition

Earth Ground:Functional earth connection. NOTE: This

connection shall be bonded to Protective Earth at the source of

supply in accordance with national and local electrical code

requirements.

Chassis Ground: Identifies a connection to the chassis or frame of

the equipment shall be bonded to Protective Earth at the source of

supply in accordance with national and local electrical code

requirements.

Symbol Definitions

viii HPM High-Performance Process Manager Service R688

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R688 HPM High-Performance Process Manager Service ix 
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Contents 
1. INTRODUCTION............................................................................................... 29 
1.1 Overview .................................................................................................................................. 29 
Introduction.......................................................................................................................................................29 
1.2 Purpose of this Manual........................................................................................................... 29 
Service philosophy ...........................................................................................................................................29 
2. EQUIPMENT DESCRIPTION............................................................................ 31 
2.1 Overview .................................................................................................................................. 31 
Introduction.......................................................................................................................................................31 
Component part numbers.................................................................................................................................31 
2.2 Power System Controls.......................................................................................................... 31 
Power Supply Module Control..........................................................................................................................31 
HPMM/IOP Card Power Interrupt Switches......................................................................................................31 
2.3 HPM Subsystem Overview..................................................................................................... 32 
Major assemblies .............................................................................................................................................32 
Card file types ..................................................................................................................................................32 
Card file designations.......................................................................................................................................33 
Nonredundant 15-Slot HPMM card file.............................................................................................................33 
Redundant 15-Slot HPMM card files ................................................................................................................33 
Nonredundant 7-Slot HPMM card file...............................................................................................................33 
Redundant 7-Slot HPMM card files..................................................................................................................33 
Nonredundant HPMM cabinet layout................................................................................................................34 
2.4 HPMM and IOP Card Files ...................................................................................................... 35 
Introduction.......................................................................................................................................................35 
HPMM and IOP card file differences ................................................................................................................35 
Non-CE Compliant card file models..................................................................................................................35 
CE Compliant card file models .........................................................................................................................35 
Conversion kit...................................................................................................................................................35 
2.5 HPMM Card Files..................................................................................................................... 35 
Introduction.......................................................................................................................................................35 
HPMM card file configurations..........................................................................................................................36 
15-Slot HPMM card file.....................................................................................................................................37 
HPMM functionality...........................................................................................................................................38 
HPMM card/module types................................................................................................................................38 
Card/module illustrations..................................................................................................................................38 
Power indicators...............................................................................................................................................39 
Status indicators...............................................................................................................................................39 
Diagnostic display ............................................................................................................................................39 
Diagnostic display analysis example................................................................................................................40 
Detailed Diagnostic display switch ...................................................................................................................40 
Debug connector..............................................................................................................................................40 
HPMM +5 volt power margins ..........................................................................................................................41 
HPM UCN Interface module illustration............................................................................................................41 
High-Performance Comm/Control card ............................................................................................................42 
High-Performance I/O Link card.......................................................................................................................43 
2.6 EHPM Card Files...................................................................................................................... 44 
Introduction.......................................................................................................................................................44 
EHPM card file configurations..........................................................................................................................44 
15-Slot EHPM card file.....................................................................................................................................45 
EHPM functionality...........................................................................................................................................46 

Contents 
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EHPM card/module types................................................................................................................................. 46 
Card/module illustrations.................................................................................................................................. 47 
Power indicators............................................................................................................................................... 47 
Status indicators............................................................................................................................................... 47 
Diagnostic display............................................................................................................................................ 47 
Diagnostic display analysis example................................................................................................................ 48 
Detailed Diagnostic display switch ................................................................................................................... 48 
Debug connector.............................................................................................................................................. 48 
EHPM +5 volt power margins........................................................................................................................... 49 
EHPM FTE Interface module ........................................................................................................................... 49 
CF9 Ethernet Switch........................................................................................................................................ 50 
Enhanced High-Performance Comm/Control card........................................................................................... 50 
EHPM Front Panel LED display information..................................................................................................... 51 
2.7 Service failed EHPM cards flashed with Experion-integrated firmware............................52 
Overview.......................................................................................................................................................... 52 
EHPM Comm/Ctrl card replacement procedure............................................................................................... 52 
2.8 IOP Card Files ..........................................................................................................................55 
Introduction ...................................................................................................................................................... 55 
Total number of card files................................................................................................................................. 55 
Remote card file installation............................................................................................................................. 55 
Total number of IOPs....................................................................................................................................... 55 
15-Slot IOP card file......................................................................................................................................... 56 
Types of Input/Output Processors (IOPs) ........................................................................................................ 57 
AO and DO IOPs.............................................................................................................................................. 57 
Redundant IOPs............................................................................................................................................... 57 
Redundant HLAI IOPs...................................................................................................................................... 58 
Redundant AO IOPs ........................................................................................................................................ 59 
Low Level Multiplexer IOP (LLMux) ................................................................................................................. 60 
2.9 Field Termination Assemblies for IOP...................................................................................61 
Two types of FTAs........................................................................................................................................... 61 
Power Adapter ................................................................................................................................................. 61 
Remote Hardened Low Level Multiplexer IOP (RHMUX)................................................................................. 61 
RHMUX Thermocouple FTA ............................................................................................................................ 62 
FTA and Power Adapter installation................................................................................................................. 62 
IOP to Power Adapter connection.................................................................................................................... 63 
Power Adapter to FTA connection ................................................................................................................... 63 
Power Adapter indicators................................................................................................................................. 63 
2.10 Serial Device Interface IOP (SDI)........................................................................................63 
Introduction ...................................................................................................................................................... 63 
SDI interface configuration............................................................................................................................... 64 
EIA-232 and EIA--422/485 interfaces............................................................................................................... 65 
EIA-232 interface cable length......................................................................................................................... 65 
EIA-422/485 cable length limitation.................................................................................................................. 65 
Power Adapter installation................................................................................................................................ 65 
SDI FTA installation ......................................................................................................................................... 65 
FTA to Power Adapter interface....................................................................................................................... 65 
Model MU-TSDT02 FTA .................................................................................................................................. 65 
Model MU-TSDM02 FTA.................................................................................................................................. 65 
Model MU-TSDU02 FTA.................................................................................................................................. 65 
Cabling information.......................................................................................................................................... 65 
2.11 Serial Interface IOP (SI) .......................................................................................................66 
Introduction ...................................................................................................................................................... 66 
EIA-232 and EIA-422/485 interfaces................................................................................................................ 66 
Point-to-point or multidrop interfaces ............................................................................................................... 66 
EIA interface limitations.................................................................................................................................... 66 
Power Adapter installation................................................................................................................................ 66 
Power Adapter size.......................................................................................................................................... 66 
New SI IOP Slot Summary display to view Array points built on the SI FTA.................................................... 66 

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Model MU-TSIM12 interconnections ................................................................................................................67 
SI FTA installation ............................................................................................................................................68 
FTA to Power Adapter interface.......................................................................................................................68 
Cabling information...........................................................................................................................................68 
Model MU-TSIA12 EIA-232 interface ...............................................................................................................68 
Model MU-TSIM12 EIA-232 interface...............................................................................................................68 
Model MU-TSIM22 EIA-422/485 interface........................................................................................................68 
2.12 I/O Link Extender (Fiber Optic Link) .................................................................................. 69 
Introduction.......................................................................................................................................................69 
See the following figures ..................................................................................................................................69 
Features and guidelines...................................................................................................................................70 
Front panel indicators.......................................................................................................................................70 
Status indicator operation.................................................................................................................................70 
Standard I/O Link Extender connections nonredundant HPMM .......................................................................71 
Standard I/O Link Extender connections redundant HPMMs ...........................................................................72 
Long Distance I/O Link Extender connections nonredundant HPMM...............................................................73 
Long Distance I/O Link Extender connections redundant HPMMs...................................................................74 
2.13 Field Termination Assembly............................................................................................... 75 
Terminal Connectors........................................................................................................................................75 
FTAs types.......................................................................................................................................................75 
Model and part numbers...................................................................................................................................75 
Detailed descriptions........................................................................................................................................75 
Standard FTAs .................................................................................................................................................75 
Galvanically isolated FTAs...............................................................................................................................77 
Three physical sizes.........................................................................................................................................77 
FTA Mounting Channels...................................................................................................................................78 
Vertical orientation............................................................................................................................................79 
Horizontal orientation........................................................................................................................................79 
Typical cabinet layout.......................................................................................................................................80 
Compression or screw terminals available.......................................................................................................81 
FTA compression-type terminal connector.......................................................................................................81 
FTA fixed screw terminal connector .................................................................................................................82 
FTA removable screw-type connector..............................................................................................................82 
Galvanic Isolation Module connectors..............................................................................................................83 
Crimp pin-type terminal connector....................................................................................................................83 
Compression-type terminal connector..............................................................................................................84 
2.14 FTA Mounting Channels ..................................................................................................... 85 
Introduction.......................................................................................................................................................85 
Location............................................................................................................................................................85 
Number of FTA Mounting Channels.................................................................................................................85 
Vertical FTA Mounting Channels......................................................................................................................85 
Horizontal FTA Mounting Channels..................................................................................................................85 
Dual access cabinet installation .......................................................................................................................86 
Single access cabinet installation.....................................................................................................................88 
2.15 Power Systems .................................................................................................................... 89 
Power System features ....................................................................................................................................89 
Standard Power System...................................................................................................................................89 
48 volt battery backup time duration.................................................................................................................89 
CMOS backup time duration ............................................................................................................................90 
PSM redundancy requirements........................................................................................................................90 
Early production Standard Power System........................................................................................................91 
HPM Standard Power System..........................................................................................................................92 
AC Only Power System....................................................................................................................................93 
2.16 Power Distribution............................................................................................................... 94 
Overview ..........................................................................................................................................................94 
AC Only Power System ac power ....................................................................................................................94 
Battery Backup Module ....................................................................................................................................94 
48 Volt Battery switch.......................................................................................................................................95 

Contents 
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No battery backup (early production Standard Power System)........................................................................ 95 
No battery backup (HPM Standard Power System)......................................................................................... 96 
CMOS Battery Backup..................................................................................................................................... 96 
Standard Power System (early production)...................................................................................................... 97 
HPM Standard Power System.......................................................................................................................... 98 
AC Only Power System.................................................................................................................................... 98 
2.17 24 Vdc Power Distribution ..................................................................................................99 
Dual power distribution cables ......................................................................................................................... 99 
Standard Power System .................................................................................................................................. 99 
AC Only Power System.................................................................................................................................... 99 
Typical cabinet power distribution.................................................................................................................... 99 
2.18 Cabinet Fan Assembly ......................................................................................................100 
Introduction .................................................................................................................................................... 100 
Up to four Cabinet Fan assemblies................................................................................................................ 100 
Optional Cabinet Fan assembly..................................................................................................................... 100 
2.19 LLAI Line Frequency Clock Voltage ................................................................................100 
Introduction .................................................................................................................................................... 100 
Standard Power System ................................................................................................................................ 100 
AC Only Power System.................................................................................................................................. 100 
2.20 24 Vdc Fuse Protection .....................................................................................................101 
Card file fusing............................................................................................................................................... 101 
Fuse removal ................................................................................................................................................. 101 
Fuse extraction............................................................................................................................................... 101 
Fuse insertion................................................................................................................................................. 102 
Left 7-Slot card file......................................................................................................................................... 102 
Left 7-Slot Card File Fuse Protection............................................................................................................. 102 
Left 7-Slot HPMM card file 24 Vdc distribution............................................................................................... 103 
Left 7-Slot IOP card file 24 Vdc distribution.................................................................................................... 104 
Left 7-Slot card file backpanel fuse locations................................................................................................. 105 
Right 7-Slot card file....................................................................................................................................... 106 
Right 7-Slot Card File Backpanel Fuse Protection......................................................................................... 106 
Right 7-Slot HPMM card file 24 Vdc distribution............................................................................................. 107 
Right 7-Slot IOP card file 24 Vdc distribution................................................................................................. 108 
Right 7-Slot card file backpanel fuse locations............................................................................................... 109 
15-Slot card file.............................................................................................................................................. 110 
15-Slot Card File Backpanel Fuse Protection................................................................................................. 110 
15-Slot HPMM card file 24 Vdc distribution.................................................................................................... 111 
15-Slot IOP card file 24 Vdc distribution......................................................................................................... 112 
15-Slot card file backpanel fuse locations...................................................................................................... 113 
IOP Only card file........................................................................................................................................... 114 
IOP Only card file assemblies........................................................................................................................ 114 
IOP Only Card File Fuse Protection............................................................................................................... 115 
IOP Only card file 24 Vdc power distribution.................................................................................................. 116 
IOP Only card file backpanel fuse locations................................................................................................... 116 
FTA fuse protection........................................................................................................................................ 117 
Cabinet Fan assembly fuse protection........................................................................................................... 118 
2.21 5 Vdc Fuse Protection .......................................................................................................118 
High-Performance I/O Link card..................................................................................................................... 118 
HPMM power routing and fuses..................................................................................................................... 119 
2.22 Card File Power Cabling....................................................................................................120 
Card file power connectors............................................................................................................................. 120 
Power Distribution assemblies....................................................................................................................... 120 
Power System power connectors................................................................................................................... 120 
Power distribution examples .......................................................................................................................... 120 
Power distribution methods............................................................................................................................ 120 
15-Slot Card File with Power Distribution Assemblies.................................................................................... 121 
Two 15-Slot Card Files with Power Distribution Assemblies.......................................................................... 122 

Contents 
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Three 15-Slot Card Files ................................................................................................................................123 
Three 15-Slot Card Files with Power Distribution Assemblies........................................................................124 
Power Distribution Assemblies for redundant cabling ....................................................................................124 
2.23 I/O Link Interface Cabling ................................................................................................. 125 
Introduction.....................................................................................................................................................125 
Cable length...................................................................................................................................................126 
Redundant cables ..........................................................................................................................................126 
No cable termination.......................................................................................................................................126 
I/O Link Interface cabling - Three Card Files..................................................................................................127 
I/O Link Interface - Four Card Files ................................................................................................................128 
I/O Link Interface Cables in adjacent cabinets ...............................................................................................129 
I/O Link Interface cable shield grounding (non-CE Compliance)....................................................................129 
I/O Link Interface cable shield grounding (CE Compliance) ...........................................................................129 
Induced power surge protection .....................................................................................................................129 
New and upgraded subsystems only..............................................................................................................130 
Surge protection network power cables..........................................................................................................131 
I/O Link cable connection...............................................................................................................................131 
Typical I/O Link and power cable connection.................................................................................................132 
Power cable I/O Link protector adapters ........................................................................................................134 
2.24 IOP to FTA Cabling............................................................................................................ 135 
Introduction.....................................................................................................................................................135 
Standard FTAs ...............................................................................................................................................135 
Galvanically Isolated FTAs.............................................................................................................................135 
External cabinet installation............................................................................................................................135 
Typical cable routing.......................................................................................................................................136 
2.25 Power Adapter Cabling..................................................................................................... 137 
Introduction.....................................................................................................................................................137 
LLMux interconnections..................................................................................................................................137 
SDI interconnections ......................................................................................................................................138 
SI interconnections.........................................................................................................................................138 
2.26 UCN Cable System ............................................................................................................ 139 
Introduction.....................................................................................................................................................139 
Redundant UCN cables..................................................................................................................................140 
Cable tap types ..............................................................................................................................................141 
Cable tap usage.............................................................................................................................................141 
Isolated port identification...............................................................................................................................142 
Card file backpanel connections.....................................................................................................................142 
2.27 EUCN Cable System.......................................................................................................... 142 
Introduction.....................................................................................................................................................142 
Redundant EUCN FTE cables........................................................................................................................144 
$FTESTS Cable Error Scenarios ...................................................................................................................144 
Cable troubleshooting guidelines for EUCN...................................................................................................147 
Diagnosing Complex EUCN FTE Network Faults...........................................................................................155 
EUCN Switches..............................................................................................................................................158
Card file backpanel connections.....................................................................................................................158 
Status indicators on the FTE Switch...............................................................................................................159 
Control Firewall status indicators....................................................................................................................162 
2.28 UCN Node Address Pinning ............................................................................................. 164 
Introduction.....................................................................................................................................................164 
One or two HPMM card files...........................................................................................................................164 
Odd address pinning ......................................................................................................................................164 
Secondary HPMM determination....................................................................................................................164 
Two methods of pinning .................................................................................................................................164 
7-Slot card file pinning....................................................................................................................................165 
15-Slot card file pinning..................................................................................................................................166 
Two pinning methods .....................................................................................................................................166 
Pinning method differences............................................................................................................................166 

Contents 
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Odd number of jumpers required ................................................................................................................... 167 
Plug jumper method....................................................................................................................................... 167 
Zero-ohm jumper method............................................................................................................................... 168 
FTE Device Index Addressing........................................................................................................................ 169 
2.29 I/O Link Interface Address Pinning ..................................................................................170 
Introduction .................................................................................................................................................... 170 
I/O Link Interface configuration ...................................................................................................................... 170 
Consecutive address assignment .................................................................................................................. 170 
Two methods of pinning................................................................................................................................. 170 
Nonredundant HPMM subsystem .................................................................................................................. 171 
7-Slot card files .............................................................................................................................................. 171 
15-Slot card file redundant HPMM subsystem............................................................................................... 172 
7-Slot card file redundant HPM subsystem.................................................................................................... 172 
IOP Only card file pinning location................................................................................................................. 173 
Two pinning methods..................................................................................................................................... 173 
One method only............................................................................................................................................ 173 
Jumper method example................................................................................................................................ 174 
Zero-ohm resistor jumper pinning example.................................................................................................... 175 
2.30 Firmware/Hardware/Software Correlation.......................................................................176 
Relationship ................................................................................................................................................... 176 
3. UCN STATUS DISPLAYS ...............................................................................179 
3.1 Overview.................................................................................................................................179 
Introduction .................................................................................................................................................... 179 
References..................................................................................................................................................... 179 
Release 600 software displays....................................................................................................................... 179 
3.2 Display Definitions ................................................................................................................179 
IOM definition................................................................................................................................................. 179 
Target selection.............................................................................................................................................. 179 
NIM Detail Status Displays............................................................................................................................. 179 
HPMM Detail Status Displays ........................................................................................................................ 180 
IOP Detail Status Displays............................................................................................................................. 180 
3.3 Detail Status Display Selection Procedures.......................................................................180 
Introduction .................................................................................................................................................... 180 
NIM Detail Status Display procedure ............................................................................................................. 180 
System Status display.................................................................................................................................... 181 
UCN Status display........................................................................................................................................ 182 
NIM Detail Status display............................................................................................................................... 184 
HPMM Detail Status Display procedure......................................................................................................... 185 
HPM Status display........................................................................................................................................ 185 
Primary HPMM Detail Status display ............................................................................................................. 187 
Secondary HPMM Detail Status display......................................................................................................... 188 
IOP Detail Status Display procedure.............................................................................................................. 189 
IOP Detail Status display ............................................................................................................................... 189 
3.4 Display Operation..................................................................................................................190 
Introduction .................................................................................................................................................... 190 
UCN Status Displays...................................................................................................................................... 190 
Three display sections ................................................................................................................................... 191 
Device status.................................................................................................................................................. 191 
Auxillary status............................................................................................................................................... 192 
Selecting the status box target....................................................................................................................... 192 
Primary HPMM status .................................................................................................................................... 192 
Secondary HPMM status ............................................................................................................................... 193 
LOAD/SAVE RESTORE Target..................................................................................................................... 194 
CONTROL STATES Target ........................................................................................................................... 196 
AUTO CHECKPT Target................................................................................................................................ 198 

Contents 
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UCN CABLE STATUS Target ........................................................................................................................200 
RUN STATES Target .....................................................................................................................................207 
SLOT SUMMARY Target ...............................................................................................................................209 
DETAIL STATUS Target ................................................................................................................................211 
System Error Journal Messages ....................................................................................................................211 
3.5 HPM Status Displays............................................................................................................. 211 
Introduction.....................................................................................................................................................211 
HPM Status Displays......................................................................................................................................211 
Primary and secondary HPMMs.....................................................................................................................212 
HPMM node number ......................................................................................................................................213 
HPMM operational states...............................................................................................................................213 
Primary HPMM status.....................................................................................................................................213 
Secondary HPMM status................................................................................................................................214 
40 IOP status boxes.......................................................................................................................................214 
IOP status box definitions...............................................................................................................................214 
IOP synchronization status.............................................................................................................................214 
IOP status states............................................................................................................................................214 
IOP A status states.........................................................................................................................................215 
IOP B status states.........................................................................................................................................216 
Command targets...........................................................................................................................................216 
LOAD/SAVE RESTORE Target .....................................................................................................................217 
LOAD/SAVE RESTORE display targets.........................................................................................................218 
CONTROL STATES target.............................................................................................................................219 
CONTROL STATES display targets...............................................................................................................219 
AUTO CHECKPT target.................................................................................................................................219 
AUTO CHECKPT display targets ...................................................................................................................220 
IOL CABLE COMMANDS target ....................................................................................................................221 
IOL CABLE COMMANDS display targets.......................................................................................................222 
RUN STATES target.......................................................................................................................................223 
RUN STATES display targets.........................................................................................................................224 
SLOT SUMMARY target.................................................................................................................................225 
REGULATORY CONTROL POINTS target....................................................................................................226 
Process Module Points display targets...........................................................................................................226 
DETAIL STATUS target..................................................................................................................................226 
3.6 NIM Detail Status Displays................................................................................................... 227 
Selection procedure........................................................................................................................................227 
NIM Driver Configuration display....................................................................................................................227 
NIM Driver Configuration display status .........................................................................................................228 
UCN Driver statistics (UCN STATS target).....................................................................................................228 
NIM and HPMM display differences ...............................................................................................................229 
Page statistical and status content.................................................................................................................229 
Switching display pages.................................................................................................................................229 
NIM Local UCN Statistics display-page 1.......................................................................................................229 
NIM Local UCN Statistics display-page 2.......................................................................................................230 
Two pages......................................................................................................................................................230 
Cable noise/silence ........................................................................................................................................230 
Time Sync operation.......................................................................................................................................230 
Four second update........................................................................................................................................231 
HELP target....................................................................................................................................................231 
3.7 HPMM Detail Status Displays............................................................................................... 232 
HPMM Detail Status display selection............................................................................................................232 
Primary HPMM Detail Status display..............................................................................................................232 
Secondary HPMM Detail Status display.........................................................................................................233 
Targets and bottom data fields.......................................................................................................................233 
Bottom data fields defined..............................................................................................................................234 
Four-second update .......................................................................................................................................234 
Target comparison..........................................................................................................................................234 
HPMM I/O Link Information display................................................................................................................235 
Primary HPMM I/O Link Information display...................................................................................................235 

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Secondary HPMM I/O Link Information display.............................................................................................. 236 
Four -second update...................................................................................................................................... 236 
HPMM I/O Link status .................................................................................................................................... 237 
HPMM IOM I/O Link Information display........................................................................................................ 239 
Data tables..................................................................................................................................................... 239 
DSA data fields .............................................................................................................................................. 240 
HPMM Version/Revision Display.................................................................................................................... 241 
Version and revision data............................................................................................................................... 242 
HPMM Control Configuration Display............................................................................................................. 243 
HPMM Write Lockout Control Display............................................................................................................ 243 
Control Configuration display information ...................................................................................................... 244 
Schedule Overrun Counters........................................................................................................................... 245 
HPM Write Lockout Displays.......................................................................................................................... 245 
HPMM Schedule Information Display............................................................................................................. 248 
HPMM UCN Statistics Displays...................................................................................................................... 249 
HPMM Maintenance Support Displays........................................................................................................... 251 
Manufacturing Information display ................................................................................................................. 258 
HPMM Soft Failure Displays .......................................................................................................................... 259 
3.8IOP Detail Status Displays....................................................................................................262 
Overview........................................................................................................................................................ 262 
Top portion of display..................................................................................................................................... 262 
Primary and secondary IOP displays ............................................................................................................. 262 
Bottom of display............................................................................................................................................ 263 
IOP configuration ........................................................................................................................................... 263 
I/O Link cable status and statistics................................................................................................................. 264 
Status messages............................................................................................................................................ 264 
Loss of communications................................................................................................................................. 265 
4-second data update .................................................................................................................................... 265 
IOP Box Soft Failures Displays...................................................................................................................... 265 
IOP Slot Soft Failures Displays...................................................................................................................... 270 
IOP Slots with Soft Failures Display............................................................................................................... 273 
HLAI IOP Detail Status Display...................................................................................................................... 273 
LLAI IOP Detail Status Display....................................................................................................................... 275 
AO IOP Detail Status Display......................................................................................................................... 280 
LLMux IOP Detail Status Display ................................................................................................................... 284 
RHMUX IOP Detail Status Display................................................................................................................. 286 
DI IOP Detail Status Display .......................................................................................................................... 289 
DO IOP Detail Status Display......................................................................................................................... 290 
STI/STIM IOP Detail Status Display............................................................................................................... 292 
PI IOP Detail Status Display........................................................................................................................... 293 
SDI IOP Detail Status Display........................................................................................................................ 294 
SI IOP Detail Status Display........................................................................................................................... 295 
DISOE IOP Detail Status Display................................................................................................................... 296 
4. FAULT ISOLATION.........................................................................................301 
4.1 Overview.................................................................................................................................301 
Purpose.......................................................................................................................................................... 301 
Release 500 software displays....................................................................................................................... 301 
4.2 Failure Types..........................................................................................................................301 
Two types of failures...................................................................................................................................... 301 
Hard failure..................................................................................................................................................... 301 
Soft failure...................................................................................................................................................... 301 
Hard and Soft failures .................................................................................................................................... 301 
HPM failure .................................................................................................................................................... 301 
HPMM Hard failure......................................................................................................................................... 302 
HPM Partial failure......................................................................................................................................... 302 
HPMM Soft failure.......................................................................................................................................... 302 
IOP Hard failure ............................................................................................................................................. 302 

Contents 
R688 HPM High-Performance Process Manager Service xvii 
December 2020 Honeywell 
IOP Soft failure...............................................................................................................................................302 
4.3 Fault Isolation Concepts ...................................................................................................... 303 
Introduction.....................................................................................................................................................303 
Troubleshooting flowcharts.............................................................................................................................303 
Recommendations for Operators and Service Technicians............................................................................304 
Troubleshooting table usage..........................................................................................................................304 
Troubleshooting Flow Chart ...........................................................................................................................306 
HPMM Corrective Actions ..............................................................................................................................312 
I/O Link overruns............................................................................................................................................314 
I/O Link overruns corrective actions ...............................................................................................................315 
Comm/Control Hard failure codes ..................................................................................................................315 
HPMM Soft Failure Codes..............................................................................................................................335 
Comm/Control Soft failure error codes...........................................................................................................337 
I/O Link processor Hard failure error codes....................................................................................................340 
IOP Hard failure error codes...........................................................................................................................341 
IOP Box Soft failure error codes.....................................................................................................................343 
IOP Slot Soft failure error codes.....................................................................................................................348 
Additional Troubleshooting for EUCN nodes..................................................................................................349 
4.4 Smart Transmitter Interface ................................................................................................. 350 
Introduction.....................................................................................................................................................350 
STI IOP and FTA faults ..................................................................................................................................350 
Two wire link or Smart Transmitter faults .......................................................................................................351 
4.5 FTA Redundancy Indicators ................................................................................................ 351 
Introduction.....................................................................................................................................................351 
AO FTA redundancy indicator........................................................................................................................351 
HLAI FTA redundancy indicator .....................................................................................................................351 
4.6 Redundant Analog Output IOP Failure Diagnosis............................................................. 351 
Introduction.....................................................................................................................................................351 
Considerations ...............................................................................................................................................352 
Avoid removing IOP A....................................................................................................................................352 
IOP A preference............................................................................................................................................352 
Replacing the FTA switching module .............................................................................................................352 
Switch to IOP A when a Soft failure occurs....................................................................................................352 
Consider use of an AO Standby Manual device.............................................................................................352 
OK/CNF [S] status..........................................................................................................................................353 
Replacing the switching module.....................................................................................................................353 
[S] CNF/OK status..........................................................................................................................................353 
Best solution when replacing switching module .............................................................................................353 
Switching module replacement procedure......................................................................................................354 
IOP B should be secondary............................................................................................................................354 
4.7 Battery Backup Exhaustion ................................................................................................. 354 
Introduction.....................................................................................................................................................354 
Loss of 24 Vdc................................................................................................................................................354 
Multiple battery backup...................................................................................................................................354 
US response to 48 Vdc battery failure............................................................................................................354 
4.8 HPMM Card and Module Indicators..................................................................................... 355 
Application of power.......................................................................................................................................355 
Status indicators and Alphanumeric display...................................................................................................355 
HPM UCN Interface module...........................................................................................................................355 
Indicator functionality......................................................................................................................................355 
High-Performance Comm/Control card Status indicator.................................................................................356 
High-Performance I/O Link card Status indicator ...........................................................................................356 
HPM UCN Interface module Transmit indicator..............................................................................................357 
Power and Status indicators...........................................................................................................................357 
HPMM fuse.....................................................................................................................................................357 
UCN Interface Module fuse............................................................................................................................357 
HPMM Card extractors...................................................................................................................................357 

Contents 
xviii HPM High-Performance Process Manager Service R688 
 Honeywell December 2020 
4.9 HPMM Alphanumeric Display...............................................................................................358 
Introduction .................................................................................................................................................... 358 
Detailed Display switch .................................................................................................................................. 358 
Rapidly changing of display contents............................................................................................................. 358 
Alphanumeric Display Format........................................................................................................................ 358 
Notification Displays....................................................................................................................................... 363 
Cold HPMM Startup Display Sequences........................................................................................................ 363 
HPMM Load display sequence....................................................................................................................... 365 
Nonredundant HPM Failure Sequences (After Load)..................................................................................... 366 
HPMM RAM Retention Startup Sequence ..................................................................................................... 368 
HPMM Redundancy Display Sequences ....................................................................................................... 369 
HPMM Alphanumeric Display Blanking.......................................................................................................... 371 
HPMM Diagnostic Tests List.......................................................................................................................... 372 
4.10 HPM Alternate Private Path...............................................................................................377 
Overview........................................................................................................................................................ 377
Equipment and Revision Requirements......................................................................................................... 378 
HPPM Redundancy Restoration Procedure................................................................................................... 378 
4.11 I/O Card Indicators.............................................................................................................380 
Loss of Power ................................................................................................................................................ 380 
Overview........................................................................................................................................................ 380 
Indicator functionality ..................................................................................................................................... 380 
Multifunctional Status indicator....................................................................................................................... 381 
4.12 FTA Indicators....................................................................................................................381 
Introduction .................................................................................................................................................... 381 
FTA indicator functions .................................................................................................................................. 381 
4.13 Power System Indicators ..................................................................................................382 
Standard Power System ................................................................................................................................ 382 
AC Only Power System.................................................................................................................................. 385 
4.14 Power System Voltage Checks.........................................................................................385 
Introduction .................................................................................................................................................... 385 
Standard Power System ................................................................................................................................ 386 
AC Only Power System.................................................................................................................................. 388 
5. UCN EXERCISER............................................................................................391 
5.1 Overview.................................................................................................................................391 
Purpose.......................................................................................................................................................... 391 
5.2 Applications ...........................................................................................................................391 
Purpose.......................................................................................................................................................... 391 
Two part test .................................................................................................................................................. 391 
5.3 Request Data Response (RDR) Test....................................................................................392 
Introduction .................................................................................................................................................... 392 
RDR protocol.................................................................................................................................................. 392 
5.4 Triangulation Test..................................................................................................................393 
Introduction .................................................................................................................................................... 393 
Timeout policy................................................................................................................................................ 393 
5.5 Test Operation .......................................................................................................................394 
UCN Exerciser operation ............................................................................................................................... 394 
Starting the UCN Exerciser............................................................................................................................ 394 
PAGE target................................................................................................................................................... 394 
HELP target.................................................................................................................................................... 394 
UCN Exerciser Overview display Page 1....................................................................................................... 394 
UCN Exerciser Overview display Page 2....................................................................................................... 394 
UCN Exerciser Help display........................................................................................................................... 395 

Contents 
R688 HPM High-Performance Process Manager Service xix 
December 2020 Honeywell 
Connection Test Summary display –Page 1..................................................................................................395 
Connection Test Summary display –Page 2..................................................................................................397 
UCN Exerciser test procedure........................................................................................................................397 
5.6 Analyzing Results ................................................................................................................. 399 
Connect Test Detail display............................................................................................................................399 
Number of attempt errors ...............................................................................................................................399 
Problem correction .........................................................................................................................................399 
6. REMOVAL AND REPLACEMENT.................................................................. 401 
6.1 Overview ................................................................................................................................ 401 
Introduction.....................................................................................................................................................401 
Electrostatic Discharge Protection..................................................................................................................401 
6.2 ESD Guidelines for HPMM and IOP Cards.......................................................................... 402 
Static discharge effects ..................................................................................................................................402 
ESD kit ...........................................................................................................................................................402 
Building a static discharge probe....................................................................................................................402 
ESD prevention rules......................................................................................................................................403 
6.3 HPMM and IOP Cards............................................................................................................ 404 
Removal and Replacement............................................................................................................................404 
HPMM and IOP card removal and replacement.............................................................................................404 
HPM UCN Interface module removal and replacement..................................................................................404 
Tightening the knurled screw..........................................................................................................................405 
HPM UCN Interface module...........................................................................................................................405 
EHPM FTE module installation.......................................................................................................................406 
6.4 Standby Manual Device Overview....................................................................................... 407 
Introduction.....................................................................................................................................................407 
No external power source option....................................................................................................................407 
Standby Manual device connections..............................................................................................................407 
DO Standby Manual device connection..........................................................................................................408 
Device interchangeability................................................................................................................................409 
DIN to phone connector adaptor cable...........................................................................................................409 
Board revision level........................................................................................................................................409 
6.5 AO Standby Manual Device Operation................................................................................ 409 
Purpose..........................................................................................................................................................409 
Two models....................................................................................................................................................409 
Original Analog Output Standby Manual device.............................................................................................410 
Compact Analog Output Standby Manual device...........................................................................................412 
6.6 DO Standby Manual Device Operation................................................................................ 414 
Purpose..........................................................................................................................................................414 
Secondary function.........................................................................................................................................414 
Mounting locations..........................................................................................................................................414 
Connection.....................................................................................................................................................415 
Output control switches disablement..............................................................................................................415 
Switch activation.............................................................................................................................................415 
Standby Manual device control procedure .....................................................................................................416 
Normal IOP control procedure........................................................................................................................418 
6.7 HPMM or IOP Card Case Replacement ............................................................................... 419 
Handling and installing HPM components......................................................................................................419 
Disassembly/assembly procedure..................................................................................................................419 
Card case illustration......................................................................................................................................420 
6.8 IOP to FTA Cable Replacement ........................................................................................... 421 
Nonredundant IOP cable replacement ...........................................................................................................421 
Redundant IOP cable replacement ................................................................................................................421 
FTA Replacement...........................................................................................................................................421 

Contents 
xx HPM High-Performance Process Manager Service R688 
 Honeywell December 2020 
Replacement procedure................................................................................................................................. 423 
6.9 FTA Module and Relay Replacement...................................................................................424 
Replacement procedure................................................................................................................................. 424 
LLAI Module replacement .............................................................................................................................. 424 
AO redundancy switching module replacement............................................................................................. 424 
SDI/SI module and fuse replacement............................................................................................................. 424 
Galvanic isolation module replacement.......................................................................................................... 424 
6.10 Card File Replacement ......................................................................................................425 
Replacement procedure................................................................................................................................. 425 
6.11 Power System.....................................................................................................................425 
Introduction .................................................................................................................................................... 425 
6.12 CMOS Battery Replacement .............................................................................................425 
NiCad batteries .............................................................................................................................................. 425 
Alkaline batteries............................................................................................................................................ 426 
Replacement procedure................................................................................................................................. 426 
6.13 48 V Backup Battery Replacement...................................................................................426 
Battery operational and service life................................................................................................................ 426 
Battery performance....................................................................................................................................... 426 
48 V Battery Pack end-of-life.......................................................................................................................... 426 
48 V Battery Pack service life......................................................................................................................... 427 
Battery charge voltage check procedure........................................................................................................ 427 
End of Battery Pack life check........................................................................................................................ 428 
Battery pack removal ..................................................................................................................................... 429 
Battery Pack installation................................................................................................................................. 429 
6.14 Power Supply Module Replacement................................................................................430 
Introduction .................................................................................................................................................... 430 
Replacement procedure................................................................................................................................. 430 
6.15 CMOS Backup Assembly Replacement...........................................................................431 
Introduction .................................................................................................................................................... 431 
Replacement procedure................................................................................................................................. 431 
6.16 Cabinet................................................................................................................................431 
Cabinet side panels (Markhon) ...................................................................................................................... 431 
Cabinet side panels (Rittal)............................................................................................................................ 431 
6.17 I/O Link Extender Optical Coupler Module Replacement ..............................................432 
Introduction .................................................................................................................................................... 432 
Replacement procedures............................................................................................................................... 432 
Non-CE Compliant replacement procedure.................................................................................................... 432 
CE Compliant replacement procedure........................................................................................................... 433 
Coupler adapter kit......................................................................................................................................... 434 
7. IOP CALIBRATION PROCEDURES...............................................................435 
7.1 Overview.................................................................................................................................435 
Introduction .................................................................................................................................................... 435 
No manual adjustments ................................................................................................................................. 435 
7.2 LLAI, HLAI, and AO IOP Calibration ....................................................................................435 
Common Calibration Procedures................................................................................................................... 435 
IOP or FTA substitution.................................................................................................................................. 435 
7.3 Equipment Required..............................................................................................................436 
Precision equipment is a necessity................................................................................................................ 436 
You will need precision equipment to accurately recalibrate these subsystems. ....................................................... 436 
Equipment requirements................................................................................................................................ 436 