Symphony Harmony area controller User manual

Instruction

Harmony

Harmony Area Controller

WBPEEUI230023A0

Preface

The Harmony area controller (HAC) is an area management

and control node for the Symphony Enterprise Management

and Control System. It is a powerful stand-alone controller

that has the processing speeds and storage capabilities neces-

sary for advanced, complex control applications. The controller

is a user-configurable device that receives process input and

output through a variety of analog, control, and digital Har-

mony I/O devices.

This instruction provides a description of the Harmony area

controller and its capabilities. It also includes information nec-

essary to install, operate, and maintain the controller.

NOTE: The Harmony area controller is compatible with the INFI 90

OPEN

Strategic Enterprise Management System and the INFI-NET

communication

network.

WBPEEUI230023A0

List of Effective Pages

NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed fig-

ures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.

Total number of pages in this instruction is 194, consisting of the following:

Page No. Change Date Page No. Change Date

Preface Original

List of Effective Pages Original

iii through xiii Original

1-1 through 1-15 Original

2-1 through 2-18 Original

3-1 through 3-3 Original

4-1 through 4-13 Original

5-1 through 5-17 Original

6-1 through 6-20 Original

7-1 through 7-2 Original

8-1 through 8-2 Original

9-1 through 9-4 Original

A-1 through A-2 Original

B-1 through B-14 Original

PR1-1 Original

PR2-1 through PR2-2 Original

PR3-1 through PR3-3 Original

PR4-1 through PR4-2 Original

PR5-1 through PR5-2 Original

PR6-1 through PR6-10 Original

PR7-1 through PR7-2 Original

PR8-1 through PR8-2 Original

PR9-1 through PR9-10 Original

PR10-1 through PR10-7 Original

PR11-1 through PR11-3 Original

PR12-1 through PR12-4 Original

PR13-1 Original

PR14-1 through PR14-2 Original

PR15-1 through PR15-3 Original

PR16-1 through PR16-2 Original

PR17-1 through PR17-2 Original

PR18-1 through PR18-2 Original

PR19-1 through PR19-2 Original

PR20-1 Original

PR21-1 through PR21-3 Original

PR22-1 through PR22-2 Original

Index-1 through Index-3 Original

WBPEEUI230023A0 iii

Table of Contents

Section 1 Introduction ..................................................................................................1-1

Purpose ................................................................................................................... 1-1

System Overview ...................................................................................................... 1-2

Control Network ................................................................................................... 1-2

I/O Interface ........................................................................................................ 1-4

Peer-to-Peer Communication ................................................................................ 1-5

Compatibility ........................................................................................................... 1-6

Features .................................................................................................................. 1-7

Intended User .......................................................................................................... 1-8

Instruction Content.................................................................................................. 1-8

How to Use This Instruction ..................................................................................... 1-9

Document Conventions ............................................................................................ 1-9

Glossary of Terms and Abbreviations........................................................................ 1-9

Reference Documents............................................................................................. 1-10

Abbreviated Harmony Nomenclature ...................................................................... 1-11

Related Nomenclature ............................................................................................ 1-11

Design Standards and Certifications ...................................................................... 1-12

Specifications......................................................................................................... 1-13

Section 2 Description and Operation .........................................................................2-1

Introduction............................................................................................................. 2-1

Description .............................................................................................................. 2-1

Controller Module .................................................................................................... 2-1

CPU ..................................................................................................................... 2-1

Memory ............................................................................................................ 2-2

Machine Fault Timer ........................................................................................ 2-4

Front Panel Control .......................................................................................... 2-4

Process I/O .......................................................................................................... 2-4

Network Bus Interface ...................................................................................... 2-5

Hnet Interface................................................................................................... 2-5

I/O Expander Bus Interface.............................................................................. 2-6

Station Link Interface ....................................................................................... 2-6

Redundancy Link ............................................................................................. 2-7

Serial Channels ................................................................................................ 2-7

Synchronization Link........................................................................................ 2-7

Network I/O ......................................................................................................... 2-8

Memory ............................................................................................................ 2-8

Receive............................................................................................................. 2-8

Transmit .......................................................................................................... 2-9

Messages.......................................................................................................... 2-9

Message Format ............................................................................................... 2-9

Message Transmission.................................................................................... 2-10

iv WBPEEUI230023A0

Table of Contents

(continued)

Section 2 Description and Operation

(continued)

Data Integrity..................................................................................................2-10

Docking Station......................................................................................................2-11

Network TU.........................................................................................................2-12

Communication TU.............................................................................................2-12

Hardware Keying ................................................................................................2-14

Electronic Identification..........................................................................................2-14

Operating Power .....................................................................................................2-15

Power Supply......................................................................................................2-15

Power System .....................................................................................................2-16

Status Output Alarm ..........................................................................................2-16

Power System Status ..........................................................................................2-17

Cooling...................................................................................................................2-17

Redundancy ...........................................................................................................2-18

Section 3 Installation ....................................................................................................3-1

Introduction .............................................................................................................3-1

Special Handling ......................................................................................................3-1

Unpacking and Inspection ........................................................................................3-2

Installation and Connection Sequence ......................................................................3-2

Section 4 Configuration ...............................................................................................4-1

Introduction .............................................................................................................4-1

Configuration Tools ..................................................................................................4-1

Software Licenses .....................................................................................................4-2

Addressing ...............................................................................................................4-2

Tuning .....................................................................................................................4-3

Function Codes ........................................................................................................4-3

Controller Execution .............................................................................................4-4

Exception Reporting..............................................................................................4-5

Time-Synchronization ...........................................................................................4-6

Time-Sync Master .............................................................................................4-6

Time-Stamp ......................................................................................................4-6

I/O Communication..............................................................................................4-7

Peer-to-Peer Communication.................................................................................4-7

Stations................................................................................................................4-7

Sequence of Events ...............................................................................................4-8

Simulation............................................................................................................4-8

Node Performance Statistics..................................................................................4-8

C Language Support ...........................................................................................4-10

Batch 90 Language Support................................................................................4-10

WBPEEUI230023A0 v

Table of Contents

(continued)

Section 4 Configuration

(continued)

UDF Language Support ...................................................................................... 4-10

Firmware ............................................................................................................... 4-11

Online Configuration.............................................................................................. 4-11

Operation........................................................................................................... 4-12

Procedure........................................................................................................... 4-12

Section 5 Operating Procedures .................................................................................5-1

Introduction............................................................................................................. 5-1

Controller Module .................................................................................................... 5-1

LCD Screen and Keypad ....................................................................................... 5-1

Main Status Display ......................................................................................... 5-1

Main Menu Display........................................................................................... 5-2

Status Indicators.................................................................................................. 5-5

Termination Units .................................................................................................... 5-7

Controller Operation ................................................................................................ 5-7

Operating Modes .................................................................................................. 5-8

Execute ............................................................................................................ 5-9

Configure ......................................................................................................... 5-9

Error .............................................................................................................. 5-10

Fail................................................................................................................. 5-10

Offline ............................................................................................................ 5-10

Startup .............................................................................................................. 5-10

Stop/Reset......................................................................................................... 5-11

LCD Screen and Keypad Operation..................................................................... 5-12

Menu Mode .................................................................................................... 5-12

Scroll/Select................................................................................................... 5-12

Edit ................................................................................................................ 5-13

Screen Saver .................................................................................................. 5-14

LCD Contrast ................................................................................................. 5-14

Language Selection............................................................................................. 5-14

NVRAM Initialization .......................................................................................... 5-14

NVRAM Formatting ............................................................................................ 5-15

Segment Modification ......................................................................................... 5-15

Station Interface .................................................................................................... 5-16

Remote Hnet Operation ...................................................................................... 5-16

Local Station Link Operation .............................................................................. 5-16

Bypass Stations ................................................................................................. 5-17

vi WBPEEUI230023A0

Table of Contents

(continued)

Section 6 Troubleshooting ..........................................................................................6-1

Introduction .............................................................................................................6-1

Troubleshooting Procedures......................................................................................6-1

Status Indicators ......................................................................................................6-1

Status Messages.......................................................................................................6-1

Halt Status ...........................................................................................................6-3

Offline and Error Status........................................................................................6-3

Problem Reports .....................................................................................................6-10

Cnet Communication ..........................................................................................6-10

Peer-to-Peer Communication...............................................................................6-11

I/O Block............................................................................................................6-11

Rack I/O ............................................................................................................6-12

Station ...............................................................................................................6-13

Status Report .........................................................................................................6-13

Connector Pin Assignments ....................................................................................6-18

Section 7 Maintenance .................................................................................................7-1

Introduction .............................................................................................................7-1

Preventive Maintenance Schedule .............................................................................7-1

Section 8 Repair and Replacement .............................................................................8-1

Introduction .............................................................................................................8-1

Repair ......................................................................................................................8-1

Replacement.............................................................................................................8-1

Section 9 Replacement and Spare Parts ....................................................................9-1

Introduction .............................................................................................................9-1

Controller Hardware Nomenclature...........................................................................9-1

Controller Software Nomenclature ............................................................................9-2

Cable Nomenclature .................................................................................................9-2

Miscellaneous Parts..................................................................................................9-4

Appendix A Hardware Drawings ................................................................................ A-1

Dimensions ............................................................................................................. A-1

Appendix B Software License Entry .......................................................................... B-1

Introduction ............................................................................................................ B-1

License Entry Program............................................................................................. B-1

Requirements ...................................................................................................... B-2

Install/Uninstall .................................................................................................. B-2

WBPEEUI230023A0 vii

Table of Contents

(continued)

Appendix B Software License Entry

(continued)

Communications Interface Configuration..............................................................B-3

Obtaining the Machine ID ........................................................................................B-6

Machine ID from LCD Menu .................................................................................B-6

Machine ID from License Entry Program...............................................................B-6

Requesting Software Keys ........................................................................................B-8

Software Key Request Form......................................................................................B-8

Entering and Downloading Licenses .........................................................................B-9

Licensing Troubleshooting......................................................................................B-12

Locating the License File ....................................................................................B-12

Error Codes........................................................................................................B-12

List of Procedures

No. Title

PR1 Installation Preparation

PR2 Docking Station Installation

PR3 Controller Module Installation

PR4 Termination Unit Installation

PR5 Controller Setup

PR6 Serial Port Setup

PR7 24 VDC Power Connection

PR8 SOA Connection

PR9 Peer-to-Peer Hnet Connection

PR10 I/O Hnet Connection

PR11 I/O Expander Bus Connection

PR12 Cnet Connection

PR13 Serial Port Connection

PR14 Station Link Connection

PR15 Time-Synchronization Link Connection

PR16 Controller Module Removal

PR17 Docking Station Removal

PR18 Termination Unit Removal

PR19 Wiring and Cabling Disconnection

PR20 Connections Check

PR21 Controller Initialization

PR22 Docking Station Initialization

viii WBPEEUI230023A0

List of Figures

No. Title Page

1-1. Symphony Communications Architecture ..................................................1-3

1-2. Harmony I/O Block Interface.....................................................................1-4

1-3. Harmony Rack I/O Interface......................................................................1-5

1-4. Peer-to-Peer Communication .....................................................................1-6

2-1. Harmony Area Controller...........................................................................2-2

2-2. Functional Block Diagram .........................................................................2-3

2-3. Docking Station (Back) ............................................................................2-11

2-4. Network Termination Unit .......................................................................2-13

2-5. Communication Termination Unit............................................................2-14

2-6. Power Supply ..........................................................................................2-15

3-1. Installation and Connection Flowchart.......................................................3-3

4-1. Function Block Configuration Example......................................................4-4

5-1. Controller Module Front Panel ...................................................................5-2

5-2. Main Status Display ..................................................................................5-2

5-3. Menu Display – Main Menu .......................................................................5-3

5-4. Network TU Front Panel.............................................................................5-7

5-5. Communication TU Front Panel.................................................................5-8

8-1. Replacement Flowchart .............................................................................8-2

A-1. Controller Module Dimensions.................................................................. A-1

A-2. Docking Station Dimensions..................................................................... A-2

B-1. Software Licensing Procedure ................................................................... B-1

B-2. Logical ICI Definition ................................................................................ B-4

B-3. Licenses Tab............................................................................................. B-7

B-4. Example Licenses Tab .............................................................................. B-7

B-5. Edit License Tab ..................................................................................... B-11

PR2-1. Docking Station Attachment ................................................................. PR2-2

PR3-1. Controller Module Attachment .............................................................. PR3-2

PR4-1. Termination Unit Installation................................................................ PR4-2

PR6-1. Communication TU Serial Port Jumpers ............................................... PR6-2

PR6-2. RS-485 Enable - J3 and J4................................................................... PR6-3

PR6-3. RS-232-C Enable - J3 and J4 ............................................................... PR6-4

PR6-4. DTE - J1 and J2 ................................................................................... PR6-5

PR6-5. DCE - J1 and J2................................................................................... PR6-6

PR6-6. Non Handshake - J1 and J2 ................................................................. PR6-7

PR6-7. Loopback - J1 and J2 ........................................................................... PR6-8

PR6-8. Handshake Control Signals - J5 through J12........................................ PR6-9

PR7-1. 24 VDC Power Connectors .................................................................... PR7-2

PR8-1. Docking Station SOA Connectors.......................................................... PR8-2

PR9-1. Peer-to-Peer Hnet Connectors............................................................... PR9-3

PR9-2. Controller with Peer-to-Peer Hnet Not Used........................................... PR9-4

PR9-3. Two Nonredundant Controllers ............................................................. PR9-5

PR9-4. Two Redundant Controllers .................................................................. PR9-6

PR9-5. Single Nonredundant Controller with Hnet Repeaters............................ PR9-7

WBPEEUI230023A0 ix

List of Figures

(continued)

No. Title Page

PR9-6. Single Redundant Controller with Hnet Repeaters ................................. PR9-8

PR9-7. Two Nonredundant Controllers with Hnet Repeaters.............................. PR9-9

PR9-8. Two Redundant Controllers with Hnet Repeaters................................. PR9-10

PR10-1. I/O Hnet Connectors........................................................................... PR10-3

PR10-2. Controller with I/O Hnet Not Used ...................................................... PR10-4

PR10-3. Nonredundant Controller .................................................................... PR10-5

PR10-4. Redundant Controller (Option 1) ......................................................... PR10-6

PR10-5. Redundant Controller (Option 2) ......................................................... PR10-7

PR11-1. I/O Expander Bus Connector .............................................................. PR11-2

PR11-2. I/O Expander Bus Cable Connection................................................... PR11-3

PR12-1. Redundant Controller Module Cnet Connections ................................. PR12-2

PR12-2. Intracabinet Cnet Connections ............................................................ PR12-3

PR12-3. Intercabinet Cnet Connections ............................................................ PR12-4

PR14-1. Station Link Cable Connection ............................................................ PR14-2

PR15-1. Time-Synchronization Link Connector................................................. PR15-2

PR15-2. DSOE Time-Sync Connection .............................................................. PR15-3

PR16-1. Controller Module Removal ................................................................. PR16-2

PR17-1. Docking Station Removal .................................................................... PR17-2

PR18-1. Termination Unit Removal .................................................................. PR18-2

PR19-1. Docking Station Connectors ................................................................ PR19-2

List of Tables

No. Title Page

1-1. Glossary of Terms and Abbreviations....................................................... 1-10

1-2. Reference Documents.............................................................................. 1-11

1-3. Abbreviated Harmony Nomenclature ....................................................... 1-11

1-4. Related Nomenclature ............................................................................. 1-11

1-5. Design Standards and Certifications ....................................................... 1-12

1-6. Specifications.......................................................................................... 1-13

1-7. Environmental Specifications .................................................................. 1-15

4-1. Online Configuration Conditions ............................................................. 4-12

5-1. Main Menu Options .................................................................................. 5-3

5-2. Front Panel Status Indicators.................................................................... 5-5

5-3. Controller Module Modes .......................................................................... 5-9

6-1. Status Indicators - Error Conditions.......................................................... 6-2

6-2. Halt Status Messages................................................................................ 6-4

6-3. Offline and Error Status Messages ............................................................ 6-5

6-4. I/O Block Problem Report Error Types .................................................... 6-11

xWBPEEUI230023A0

List of Tables

(continued)

No. Title Page

6-5. Status Bytes............................................................................................6-14

6-6. Status Byte Descriptions .........................................................................6-15

6-7. Status Byte 3 through 5 Error Codes .......................................................6-17

6-8. Docking Station 24 VDC (P10, P11)..........................................................6-19

6-9. Docking Station I/O Expander Bus (P18) .................................................6-19

6-10. Docking Station Hnet (P19, P20, P21, P23, P24, P25, P26) .......................6-19

6-11. Docking Station Hnet (P19, P20, P21, P23, P24, P25, P26) .......................6-20

6-12. Communication TU RS-485 Port (P2, P4) .................................................6-20

6-13. Communication TU RS-232-C Port (P3, P5) ..............................................6-20

7-1. Preventive Maintenance Schedule ..............................................................7-2

9-1. Docking Station Nomenclature ..................................................................9-1

9-2. Controller Module Nomenclature ...............................................................9-2

9-3. Controller Software Nomenclature .............................................................9-2

9-4. Cable Nomenclature ..................................................................................9-2

9-5. Miscellaneous Parts...................................................................................9-4

B-1. Licensing Error Codes, Messages, and Descriptions ................................ B-12

PR6-1. User-Configured Serial Port Jumper Settings ...................................... PR6-10

WBPEEUI230023A0 xi

Safety Summary

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precau-

tions as described in the installation section.

GENERAL

WARNINGS

Equipment Environment

All components, whether in transportation, operation or storage,

must be in a noncorrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with

energized parts is avoided when servicing.

SPECIFIC

WARNINGS

Acontrollermoduleshouldnotbeinsertedorremovedwithpower

applied when located in a class I, division 2 hazardous location

unless the area is known to be nonhazardous. (p. 2-15, PR3-1,

PR16-1)

Verify the main power and power entr y panel circuit breakers/

switches are turned off before starting installation, retrofit, upgrade,

replacement, or wiring procedures. Failure to do so could result in

severe or fatal shock. Do not turn the power on until the installation,

retrofit, upgrade, replacement, or wiring procedures are complete.

(p. PR1-1, PR19-1)

Aterminationunitshouldnotbeinsertedorremovedwithpower

applied when located in a class I, division 2 hazardous location

unless the area is known to be nonhazardous. (p. PR4-1, PR18-1)

Tu r n o f f a l l p o we r b e f o re a t t e m p ti n g t h e c o nn e c t io n s c h e ck ma i n te -

nance procedure. Failure to do so could result in severe or fatal

shock, or equipment damage. (p. PR20-1)

SPECIFIC

CAUTIONS

Release the latching mechanism by flipping the locking switch

located behind the access door up to remove a controller module.

Insure the latching mechanism is engaged (locking switch in down

position) when a controller module is installed. (p. PR3-1, PR16-1)

xii WBPEEUI230023A0

Support Services

Bailey will provide assistance in the operation and repair of its

products. Requests for sales or application services should be

made to your nearest sales or service office. Bailey can also

provide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and

part descriptions from equipment manuals. Parts without a

description must be ordered from the nearest sales or service

office. Recommended spare parts lists, including prices are

available through the nearest sales or service office.

Bailey has modern training facilities available for training your

personnel. On-site training is also available. Contact your

nearest Bailey sales office for specific information and sched-

uling.

Additional copies of this instruction, or other instructions, can

be obtained from the nearest Bailey sales office at a reasonable

charge.

WBPEEUI230023A0 xiii

Trademarks and Registrations

Registrations and trademarks used in this document include:

™ Batch 90 Trademark of Elsag Bailey Process Automation.

® INFI 90 Registered trademark of Elsag Bailey Process Automation.

® INFI-NET Registered trademark of Elsag Bailey Process Automation.

® Rainbow Registered trademark of Rainbow Technologies, Incorporated.

® SentinelSuperPro Trademark of Rainbow Technologies, Incorporated.

® Windows Registered trademark of Microsoft Corporation.

® Windows NT Registered trademark of Microsoft Corporation.

WBPEEUI230023A0

Preface

The Harmony area controller (HAC) is an area management

and control node for the Symphony Enterprise Management

and Control System. It is a powerful stand-alone controller

that has the processing speeds and storage capabilities neces-

sary for advanced, complex control applications. The controller

is a user-configurable device that receives process input and

output through a variety of analog, control, and digital Har-

mony I/O devices.

This instruction provides a description of the Harmony area

controller and its capabilities. It also includes information nec-

essary to install, operate, and maintain the controller.

NOTE: The Harmony area controller is compatible with the INFI 90

OPEN

Strategic Enterprise Management System and the INFI-NET

communication

network.

WBPEEUI230023A0

List of Effective Pages

NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed fig-

ures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.

Total number of pages in this instruction is 194, consisting of the following:

Page No. Change Date Page No. Change Date

Preface Original

List of Effective Pages Original

iii through xiii Original

1-1 through 1-15 Original

2-1 through 2-18 Original

3-1 through 3-3 Original

4-1 through 4-13 Original

5-1 through 5-17 Original

6-1 through 6-20 Original

7-1 through 7-2 Original

8-1 through 8-2 Original

9-1 through 9-4 Original

A-1 through A-2 Original

B-1 through B-14 Original

PR1-1 Original

PR2-1 through PR2-2 Original

PR3-1 through PR3-3 Original

PR4-1 through PR4-2 Original

PR5-1 through PR5-2 Original

PR6-1 through PR6-10 Original

PR7-1 through PR7-2 Original

PR8-1 through PR8-2 Original

PR9-1 through PR9-10 Original

PR10-1 through PR10-7 Original

PR11-1 through PR11-3 Original

PR12-1 through PR12-4 Original

PR13-1 Original

PR14-1 through PR14-2 Original

PR15-1 through PR15-3 Original

PR16-1 through PR16-2 Original

PR17-1 through PR17-2 Original

PR18-1 through PR18-2 Original

PR19-1 through PR19-2 Original

PR20-1 Original

PR21-1 through PR21-3 Original

PR22-1 through PR22-2 Original

Index-1 through Index-3 Original