Siemens SYSCON1 User manual

CIM Door Upgrade Page 1 IP-0021
SYSCON1/+
Procedure to Install a CIM Door Retrofit in an
Existing Airbath/Airless Maxum
(SYSCON1/SYSCON+ with 5.10 or 5.20 Software)
Difficulty Level: Medium
Estimated time to execute: 2 Hours
Revision History
Issue
Date
Reason
00A
8/18/12
Beta Draft
001
8/20/12
First Revision
002
8/28/12
Changes based on review.
003
8/29/12
Minor Change
004
10/11/12
Changes based on beta results
005
12/13/12
Change error in image. Break out sections.
006
11/11/13
Update to include Maxum I
007
1/24/14
Update for CIM cover

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1.0 Description
This document describes the procedure to replace an original version Maxum door
with a CIM (Control Interface Module) door. The primary purpose of this retrofit is to
incorporate the CIM display. This display is a color screen user interface with touch
pad control and is designed to be a greatly enhanced replacement for the legacy
HMI (Human Machine Interface) available for the Maxum. The CIM display
represents a large leap forward in usability over the HMI. Beyond the addition of
color and touch screen technology, the CIM display utilizes a much larger display
area and provides enhanced graphics and on-screen help functions.
In addition to the enhanced user display, the CIM door contains the CIM electronics
modules used to control the display. The CIM electronics are capable of performing
several functions within the Maxum, including being the processor for a Modular
Oven Configuration Maxum II. This procedure involves installation of CIM hardware
for use as a user display. For more information on the CIM display and electronics
hardware, refer to the Maintenance Manual for the Modular Oven Maxum
Note: This document is specific to Maxum (Maxum II or Advance Maxum) analyzers
configured with SYSCON1/SYSCON+. For Maxum analyzers configured with
SYSCON2, refer to the appropriate procedure (IP-0020).
Figure 1: CIM Display

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Caution: This upgrade involves multiple steps, several of which MUST be
performed in the correct order. Failure to follow all of the steps in
this procedure in the correct order will result in the upgrade failing
or the analyzer not working correctly afterwards.
This procedure must be executed by personnel who have the
knowledge necessary to complete all the required software and
hardware steps. If the user needs help with completing this
procedure then it is recommended that Siemens Field Service
personnel be contracted to assist.
The basic steps for completing this procedure are as follows. Refer to the diagrams
on the following pages.
1. Install Gas Chromatograph Portal workstation software (version 5.10) and
System Manager software (version 5.0.19), if not already installed.
2. Upgrade the analyzer to Release 4.40 and the SYSCON OS and Boot firmware,
if not already installed.
3. Modify analyzer IP addresses to support the retrofit.
4. Power down the analyzer and perform hardware installation.
5. Configure the IP address and operating mode for the new CIM.
6. Upgrade the SYSCON software to function with new IP configuration.
7. Verify the operation of the new hardware.
SYSCON1/+
External Ethernet
(or internally mounted
Ethernet device)
HMI
Door
Figure 2: Diagram of Ethernet and User Display Connections
Starting Configuration

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External Ethernet
(or internally mounted
Ethernet device)
Internal
Ethernet
SYSCON1/+
CIM
CAC3
CIM Touch Screen
Color Display
Door
Figure 3: Diagram of Ethernet and User Display Connections
Final Configuration

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2.0 Prerequisites
•The CIM door electronics require a small amount of extra power, which
translates to a small amount of extra heat inside the analyzer electronics
compartment (EC). For this reason, it must be determined whether the
internal temperature of the EC is near the allowed thermal limit, as the extra
heat could possibly put the EC above the thermal limit. Refer to Section 3 of
this procedure, Thermal Considerations, for more information.
•This procedure must be performed by a user who has detailed
knowledge of the Maxum. This includes detailed knowledge of the
hardware and operation of the device. In addition, the user must have
sufficient computer skills to be able to install and operate the Gas
Chromatograph Portal software. If a customer does not have the knowledge
required for this procedure, then it is recommended that Siemens Field
Service personnel be contracted to assist.
•The Maxum analyzer must be equipped with SYSCON1 or SYSCON+. For
analyzers equipped with SYSCON2, refer to procedure IP-0020.
•A tool kit including both standard and metric wrenches, Hex wrenches, and
screw drivers is required to perform this procedure.
Warning: Full safety precautions must be followed throughout all sections of
this procedure to prevent possible injury, equipment damage, or
death. Verify that the area is clear of flammable gases and vapors
and that appropriate authorization is obtained to do the work (hot
work permits).
A retrofit kit is required for this procedure. Due to different door configurations,
different kits exist for Maxum II (part number A5E31317779001) and Advance
Maxum (part number A5E32964707001). In both Maxum II and Advance Maxum,
the kit contains the following items.
Description
Quantity
Door assembly with installed CIM display and CIM-Board (CIM-Board
consists of the base board with installed CAC3) 1
Serial cable (for connection from SYSCON Debug to CIM Serial port)
1
“Y-shaped” Purge Cable (for splitting purge signal cable from PECM).
1
Green Ethernet cable (for connecting CIM CAC3 to ESB)
1
Short Gray Ethernet cable (for connecting SYSCON1/+ to CIM-Base)
1
Long Gray Ethernet cable (for connecting SYSCON2 to CIM-Base)
1
Power Wire for CIM I2C (white) connector to 24V (black) connector
1
Intrinsic Safety (IS) Ground wires for CIM
2
Note: The above list is included for reference only and is not intended to be all
inclusive. For a complete list with part numbers, refer to the packing list
sent with the kit.

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3.0 Thermal Considerations
The Maxum is rated to an ambient temperature of up to 50°C. However, depending on
application specific parameters, such as number of detectors, oven temperature, and
electronic loading, the acceptable ambient temperature of a particular analyzer may be
reduced.
The CIM door electronics use about 10 watts more power than the legacy HMI. This can
lead to a small increase, less than 5°C, in the internal operating temperature of the EC. It
is possible that in some heavily loaded analyzers running near the ambient thermal limit,
that this extra heat could push the internal EC past its thermal limit. In order to
accommodate the upgrade to a CIM Door, the ambient temperature needs to be low
enough to keep the internal temperature of the electronics enclosure below 60°C (before
installation of the CIM Door).
For this reason, not all analyzers may be a good candidate for upgrading to the CIM
door. To determine if a particular analyzer is a good candidate perform the following test.
Refer to Appendix 4 for more details. If desired, Siemens field service can assist with
this test (contact your Siemens representative).
Does ambient
temperature
exceed 40°C?
No
Ok to upgrade to
CIM Door
Yes
Test Ambient
Temperature
(see Appendix 4)
Test Internal EC
Temperature
(see Appendix 4)
No
Ok to upgrade to
CIM Door
Is difference
between internal
and ambient
> 10°C?
Yes
Observe new maximum
ambient (see Appendix 4)

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4.0 CIM and SYSCON Connections
This section provides figures showing the available connections for the CIM and
SYSCON.
Figure 4 – SYSCON+ Board Connections
Internal Bus
CAN Direct 1
CAN Direct 2
CAN Direct 3
CAN Direct 4
CAN Direct 5
AT Bus
PCI Slot 1
PCI Slot 2
PCI Slot 3
PCI Slot 4
10BaseT
I/O Terminal
Blocks
Maintenance
Panel Display
SIMM 72
SIMM 80 #2 Flash/SRAM
SIMM 80 #1
RS 232/488
Not Used
Not Used
SYSCON
Debug
Power
Reset
CAN Bus
Purge
10Base2

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-X01 RS-232C Port
-X02 RS-485
-X03 Maintenance Panel
Connector
-X04 Digital Outputs
(System Controller)
-X05 Analog & Digital Inputs
-X06 CAN Bus Connector
-X07–Ethernet 10Base T
-X08 Communication Board
(NetCom or Ethernet
to Fiber Optic
Converter) Slot 1
-X09 not used
-X10 Analog and Digital
I/O Board
-X11 Analog and Digital
I/O Board
-X12 10BaseT Ethernet
Board
Figure 5 – SYSCON1 Cage Connections
Original
Assembly
Newer
Assembly

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Figure 6 – CIM Board Connections

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5.0 Install/Upgrade Gas Chromatograph Portal Software (if Needed)
This section covers installing/upgrading of the workstation software. This is required to
support the various retrofit tasks later in the procedure.
Step Procedure
Note:
For additional information relating to the installation and use of Gas
Chromatograph Portal (GCP), refer to the Getting Started Manual for GCP
(part number A5E03944542001).
Note:
This section is not required if the software was installed previously.
1.
Gas Chromatograph Portal (GCP) Software for Maxum Version 4.40 is
required. To upgrade the GCP software, insert the Maxum Software
installation disk. The installation program should launch automatically.
2.
From the menu, select the System Manager Setup Wizard.
3.
Following the instructions on the screen, use the Setup Wizard to upgrade
the System Manager Software to the required version 5.0.19.
4.
After System Manager is upgraded, select the GCP Setup Wizard from the
installation menu in order to upgrade the Gas Chromatograph Portal
Software to the required version 4.40.
5.
The Setup Wizard will determine if any additional windows packages are
necessary and install them automatically. If system prompts for reboot, then
do so before continuing. Otherwise, the GCP installation may not complete
properly.
6.
Continue the installation, answering any prompts from the screen. It is
recommended that default options be selected.
7.
Repeat the installation for all computers that you wish to upgrade.

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6.0 Upgrade Maxum to Version 4.40 (if Needed)
This section covers upgrading the Maxum II to software version 4.40, along with
upgrading the SYSCON OS and Bootloader, which is a requirement for communication
with the CIM.
Step Procedure
Note:
This section is not required if the software was installed previously.
Note:
This section requires use of the Gas Chromatograph Portal (GCP)
software. For additional information relating to use of GCP, refer to the
Getting Started Manual for GCP (part number A5E03944542001).
1.
To upgrade, open the GCP Network portal and choose the correct analyzer.
Then choose the Software Upgrade button at the top of the window. After
logging in, a window similar to the window below is displayed.
If all applications are not already in hold, then place them in hold at this
time using the “Hold all Applications” button, and then wait for all currently
running cycles to complete.
Verify that “Upgrade4.40” is selected. The upgrade tool will determine
based on the existing configuration and the target version which items to
upgrade (which can be seen with the “Show Details” button, if desired).

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Step Procedure
2.
Hit OK to begin the upgrade. The upgrade will take several minutes, during
which time a series of messages detailing the progress of the upgrade will
be displayed. Monitor for any errors.
Note: At one point during the upgrade a DBConverter window will pop up.
This is an automatic function of the upgrade script. No user intervention is
necessary.
3.
When the upgrade is finished, the following message should be displayed.
Click OK to continue.
Note that if the above window is not displayed then the upgrade may not
have completed successfully.

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7.0 Modify IP Addresses for the SYSCON
This section covers the final step before replacing the hardware. The IP addresses
stored in the SYSCON must be modified to communicate with the CIM (after it is
installed the CIM will be configured with the site specific IP address information for the
analyzer).
Step Procedure
Note:
With the CIM door installed, the CIM will control the IP communication
for the analyzer. In this configuration the SYSCON communicates with
the CIM using a uniform set of IP settings.
To change the SYSCON IP settings, all addresses must be set at the
same time using the form in the HMI emulator for GCP. This is due to
the fact that the device will no longer communicate on the LAN once
one address is changed.
CAUTION: The steps in this section must be executed exactly as
described. Entering an incorrect IP address will make it impossible to
communicate with the device after the upgrade.
Note:
This section requires use of the Gas Chromatograph Portal (GCP)
software. For additional information relating to use of GCP, refer to the
Getting Started Manual for GCP (part number A5E03944542001).
This section also requires use of the HMI emulator. Since the software was
upgraded, this will be the new emulator that looks the same as the CIM
Display. More information on the use of this can be found in appendix 3 at
the end of this procedure.
1.
Open the HMI emulator for the device using the GCP software.
2.
If the analyzer is not already in hold, put it in hold at this time (click Hold on
the upper middle part of the emulator window).
3.
The Configure Menu is selected by choosing the icon in the lower right
portion of the emulator window. On the HMI emulator select the Configure
Menu and then select the “System Setup” menu item.
4.
From the System Setup screen select “IP SET INFO” at the bottom of the
screen, and then choose “LAN 1 IP adr” from the table.
Write down the LAN 1 IP Adr, the LAN 1 IP Mask, and the Router 1 IP Adr
settings for later use. These will be programmed into the CIM.

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Step Procedure
Note
Entering an incorrect IP address in the following step will make it
impossible to communicate with the device after the upgrade without
changing the address using the bootloader.
5.
On the IP setting screen hit the “Modify” softkey. This will bring up the
following window.
Enter the numbers exactly as shown above and then click OK. These are
settings that will be required to communicate with the CIM via internal IP
bus.
6.
Once the IP addresses have been changed, close the HMI emulator and
the GCP connection. Note that depending on the configuration and timing
the software may freeze for several seconds while waiting for network
response.
7.
Continue with the next section, Analyzer Door Replacement, immediately.

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8.0 Analyzer Door Replacement
This section covers replacing the original door with the new CIM door. Refer to figures in
the previous section titled CIM and SYSCON Connections for connector locations.
Step Procedure
Warning: Full safety precautions must be followed throughout this
procedure to prevent possible injury, equipment damage, or death.
Verify that the area is clear of flammable gases and vapors and that
appropriate authorization is obtained to do the work.
1.
Using a hex wrench, remove the protective cover from the CIM board on
the new CIM door. Set the cover aside until the procedure is complete.
2.
Using appropriate safety precautions, power down the analyzer.
3.
After appropriate safety precautions have been followed, open the door to
the Electronics Enclosure (EC)
4.
Disconnect the HMI cable from SYSCON cage by loosening the fastening
screws and then pulling the connector out. Also, disconnect the HMI cable
from any clips that affix the cable to the EC (see below). Leave the cable
plugged in at the HMI end.
HMI Cable Connected to SYSCON Cage
Connector Clip
Note: In some configurations the ribbon cable may be covered in a shield
and this shield may have a ground wire connecting to the frame of the
SYSCON cage. If this is the case it will also be necessary to disconnect
that ground wire from the cage. This wire will not be used in the new
configuration.

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Step Procedure
5.
Unscrew the two nuts that secure the SYSCON cage, and pull the cage out
to the dropped-down position as shown below.
Note
Because the CIM door has extra hardware mounted on the inside, it is
possible that hardware mounted on the front of the SYSCON cage may
bump against the CIM hardware, preventing the door from closing.
Changes may need to be made in order for all hardware to have the correct
clearance.
6.
User installed wiring going to the orange I/O connectors on the front of the
SYSCON cage must be dressed in such a way that they do not prevent the
door from closing. This means that the wires should bend at a right angle
close to the connector (not stick out) and should preferably be tied together
as shown below.

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Step Procedure
Note:
There are multiple revisions of the SYSCON Cage (refer back to figure 5 in
the previous chapter). Older versions of the cage have a CAN bus
connector on the front, used to connect to a CAN Extension Unit, if
equipped. In newer versions this connector is on the side. If the connector
is on the front, then it must be modified as described in either of the
following two steps (depending on the configuration).
7.
(Use this step if CAN connector is located on the front of the SYSCON cage
and is equipped with a bus termination plug)
In many cases the CAN connector will not be in use and will be equipped
with a terminator plug. If this is the case, use this step to move the
connector so that it will not contact the CIM. (If the connector is in use with
a cable attached, refer to step 7).
A) Remove the terminator plug (unscrew silver sleeve). Then, remove the
plug from the cage by unscrewing the nut using a 14mm wrench.
B) Screw the terminator plug back onto the connector. Then, secure the
connector to the inside of the cage with a cable tie as shown.

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Step Procedure
8.
(Use this step if CAN connector is located on the front of the SYSCON cage
and is in use with a connected cable)
In cases WHERE the CAN connector is in use (connected to a CAN Extension
Unit), the connector must be moved as described below in order to prevent the
connector from pressing against the CIM.
A) Remove the cable (unscrew silver sleeve). Then, remove the plug from the
cage by unscrewing the nut using a 14mm wrench. Unplug the CAN plug cable
from the SYSCON board.
B) Remove the side panel from the cage by loosening the thumbscrews. Then,
remove the HMI connector using a hex wrench (size 3/32”).