Procedure to Install a CIM Door Retrofit in an Existing Airbath/Airless Maxum (SYSCON1/SYSCON+ with 5.10 or 5.20 Software)

Transcription

1 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 /29/12 Minor Change /11/12 Changes based on beta results /13/12 Change error in image. Break out sections /11/13 Update to include Maxum I 007 1/24/14 Update for CIM cover CIM Door Upgrade Page 1 IP-0021

2 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 CIM Door Upgrade Page 2 IP-0021

3 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 ), 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. External Ethernet (or internally mounted Ethernet device) HMI Door Figure 2: Diagram of Ethernet and User Display Connections Starting Configuration CIM Door Upgrade Page 3 IP-0021

4 Internal Ethernet External Ethernet (or internally mounted Ethernet device) CAC3 CIM CIM Touch Screen Color Display Door Figure 3: Diagram of Ethernet and User Display Connections Final Configuration CIM Door Upgrade Page 4 IP-0021

5 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 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 A5E ) and Advance Maxum (part number A5E ). 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 to CIM-Base) 1 Long Gray Ethernet cable (for connecting SYSCON2 to CIM-Base) 1 Power Wire for CIM I 2 C (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. CIM Door Upgrade Page 5 IP-0021

6 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) Is difference between internal and ambient > 10 C? No Ok to upgrade to CIM Door Yes Observe new maximum ambient (see Appendix 4) CIM Door Upgrade Page 6 IP-0021

7 4.0 CIM and SYSCON Connections This section provides figures showing the available connections for the CIM and SYSCON. Reset SIMM 80 #2 Flash/SRAM SIMM 80 #1 SIMM 72 Maintenance Panel Display CAN Direct 5 CAN Direct 4 CAN Direct 3 CAN Direct 2 Power Purge RS 232/488 Not Used Not Used SYSCON Debug CAN Bus I/O Terminal Blocks 10BaseT Internal Bus CAN Direct 1 AT Bus PCI Slot 4 10Base2 PCI Slot 3 PCI Slot 2 PCI Slot 1 Figure 4 SYSCON+ Board Connections CIM Door Upgrade Page 7 IP-0021

8 Original Assembly Newer Assembly -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 CIM Door Upgrade Page 8 IP-0021

9 Figure 6 CIM Board Connections CIM Door Upgrade Page 9 IP-0021

10 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 Note: 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 A5E ). 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 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 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. CIM Door Upgrade Page 10 IP-0021

11 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 Note: Note: This section is not required if the software was installed previously. 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 A5E ). 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). CIM Door Upgrade Page 11 IP-0021

12 Step 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. CIM Door Upgrade Page 12 IP-0021

13 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 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 A5E ). 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. CIM Door Upgrade Page 13 IP-0021

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15 Step 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. CIM Door Upgrade Page 15 IP-0021

16 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 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. CIM Door Upgrade Page 16 IP-0021

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18 Step 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. CIM Door Upgrade Page 18 IP-0021

19 Step 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. CIM Door Upgrade Page 19 IP-0021

20 Step 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 ). CIM Door Upgrade Page 20 IP-0021

21 Step 7. Cont: (continued from previous page) C) Next, remove the HMI connector from the SYSCON by spreading blue connector clips and pulling. D) Feed the flat part of the CAN connector cable through the HMI connector hole. Plug the cable in to the SYSCON board in the same location that it was plugged in previously. E) Replace the side panel of the cage and secure using the thumb screws. Then, secure the connector to the inside of the cage with a cable tie as shown CIM Door Upgrade Page 21 IP-0021

22 Step 9. Remove the ground lugs from the door end. These will be reused on the new door. 10. If equipped, remove the HMI to EC ground wire at the EC end. This wire will not be reused. CIM Door Upgrade Page 22 IP-0021

23 Step 11. Remove door by lifting off hinges. 12. Install new door onto hinges. CIM Door Upgrade Page 23 IP-0021

24 Step 13. Remove the purge cable running from the SYSCON to the PECM. SYSCON End PECM End (PECM2 shown. PECM1 has similar location.) CIM Door Upgrade Page 24 IP-0021

25 Step Note: In some older versions of analyzer there may be a short connector wire installed in line with the original purge cable running to the SYSCON (see below). This is a purge bypass cable used to disable the purge alarm. If this is installed it should remain installed in the same location. The SYSCON end of the Y-shaped cable will plug into the bypass cable. 14. On the new CIM, verify that the switch settings are correct. CPLD Spare switches should all be Off (down). The I 2 C Bus Pull-Up switches should all be On (to the left). CIM Door Upgrade Page 25 IP-0021

26 Step 15. Connect Y-shaped purge cable from PECM to both CIM and SYSCON. CIM End PECM End SYSCON End CIM Door Upgrade Page 26 IP-0021

27 Step Note: In the following steps the Ethernet cables are to be routed inside the Electronics Enclosure along the bottom in such a way that any excess is kept out of the way. 16. Remove the existing Ethernet cable from the front of the SYSCON cage. This may be a directly connected external cable or it may be connected to another device, such as a fiber converter board, inside the Electronics Enclosure (EC). If the cable is connected to a device in the EC, disconnect it at both ends. 17. Install the short gray Ethernet cable from the kit, plugging it into the RJ-45 Ethernet port on the front of the SYSCON cage and the RJ-45 connector on the CIM-Base board as shown below. SYSCON End CIM End CIM Door Upgrade Page 27 IP-0021

28 Step 18. If the original Ethernet cable was connected to a device inside the Electronics Enclosure (EC), install the green Ethernet cable from the kit, plugging it into the CAC3 on the CIM and into other device where the original cable was connected. If an external Ethernet cable was connected directly to the Ethernet port on the SYSCON cage, then connect that cable to the CAC3 on the CIM (the green Ethernet cable will not be used in this configuration). CIM End CIM Door Upgrade Page 28 IP-0021

29 Step 19. Install the serial cable from the SYSCON Debug Port on the front of the SYSCON cage to Serial Port 1 on the CIM-Base board (not the CIM debug port). SYSCON End CIM End 20. Connect the ground clips from the door to the EC. CIM Door Upgrade Page 29 IP-0021

30 Step 21. Install Intrinsic Safety ground wires from the CIM to the EC. These must attach to separate ground posts in the EC. The two posts near the back of the EC, just above the PECM, should be used if possible. Ground posts IS Grounds Attached CIM IS Ground Connections CIM Door Upgrade Page 30 IP-0021

31 Step Note: Power wiring for the CIM door is accomplished using a specially designed cable (see below) that plugs into a free WDB I 2 C connector. This differs slightly from power for a CIM that is shipped with a new analyzer. The retrofit is done in this manner in order for the door to be compatible with all legacy power configurations (such as PECM1). 22. Power connection at WDB end: Plug the white I 2 C connector of the power cable into any unused WDB I 2 C connection. Empty Connector Power Cable Connected Note: The power cable should run across the back of the EC and then towards the front, adjacent to the PECM. CIM Door Upgrade Page 31 IP-0021

32 Step 23. Power connection at CIM end: Run the other end of the power cable to the CIM and plug it into the P2 power connector (left connector) on the CIM. 24. Secure all cables to the cable tie bracket on the CIM door. 25. Before powering up the device, temporarily unplug the green Ethernet cable from the CIM. This is to prevent the device from possibly broadcasting the default IP address of the CIM on the network. CIM Door Upgrade Page 32 IP-0021

33 9.0 Configure IP Addresses and Operating Mode Step Note: The following steps require the user to enter the bootloader menu on the CIM display. This menu is accessible at the time of power up. The IP settings and the CIM Device Mode need to be set. 1. Apply power to the analyzer. The startup screen should appear on the CIM display. 2. Wait for the message To enter the bootloader menu, press the Home key now. At that point press the Home key on the screen and the boot menu should appear. 3. Choose selection 5 (Configuration...) on the bootloader menu. Note: Important: In when no router (default gateway) is used, the IP address for the router is set to This is not valid for the CIM settings in the following step. When no router is used, the CIM requires the IP address for this parameter to be set to the IP Address of the analyzer. 4. To change the IP settings press 2 on the Configuration menu (Primary Ethernet IP Configuration). The system will proceed with a list of questions. Read each question carefully and follow the instructions to questions on the screen to change the IP settings. These are the customer specific IP settings that were set for the SYSCON before the SYSCON IP settings were changed. Note: At this time only change the IP Address, the Subnet Mask (if different), and the Default Gateway Address. Note that if the Default Gateway is not used, then the IP Address of the analyzer is used for the Default Gateway. After entering an address, the Home key is used as an Enter key to accept the change. 5. The Device Mode identifies if the CIM is operating as a user display or as the control module for an analyzer. To change the Device Mode press selection 4 (Choose device mode) on the bootloader Configuration Menu. Set the mode for the CIM to operate as a touch screen display for the SYSCON1 ( User Interface connected to SYSCON1 ). At this point the CIM will reboot automatically Note: Although the IP settings are now correct, they will not display correctly if the user tries to display them on the new CIM display (the internal settings for the SYSCON will be displayed). The step on the next page must be completed first. CIM Door Upgrade Page 33 IP-0021

34 Step 6. Now that the IP settings for the CIM are correct, plug the green Ethernet cable back into the CIM. 7. Allow the analyzer to reboot and allow it to come up. 8. Using a hex wrench, replace the protective cover on the CIM board. CIM Door Upgrade Page 34 IP-0021

35 10.0 Upgrade SYSCON Software to Function with New CIM Step Note: Although it may appear that the analyzer is communicating, not all communications and IP configurations are functional yet (for example, the display will only show the internal SYSCON IP settings rather than the correct network IP settings). At this point the user must update the SYSCON so that the database can correctly operate with the new IP settings as shown in the following step. 1. This step updates the SYSCON so that it will correctly identify that it is working on an internal network through the CIM. Open the GCP Network portal and highlight the line for the correct analyzer. Then choose the Software Upgrade button at the top of the window. After logging in, the upgrade window is displayed. Choose the Show Details button. The window below should be displayed. Uncheck all items except for Database Scripts. Then click OK. The upgrade window should appear. Monitor the status and verify the process completes successfully. CIM Door Upgrade Page 35 IP-0021

36 11.0 Verify Operation Step 1. Verify that the purge alarm LED and all other LEDs work as expected. If the analyzer is set up for purge alarm, then when purge pressure is lost (door open), the alarm LED should be flashing. The LED should turn off when the door is closed and the electronics enclosure has purge pressure. If the analyzer is set up to bypass the purge alarm, then the LED should not be lit when the door is open. 2. Verify that the CIM display works as expected. Refer to Appendix 3 on page 41 for instructions relating to use of the CIM display. Access a table, such as the Temperature Controller table. This can be done by tapping the icon labeled Temp on the right side of the screen. Access the context sensitive Help, but touching the help icon ( ) on the upper right corner of the CIM display. Then, touch another item on the screen, such as a menu selection. A dialog box should appear that displays information about the item. Verify the IP addresses for the analyzer. This can be done by choosing the icon labeled Configure on the lower right hand side of the screen. This brings up the Configure menu. Then tap the System Setup menu item and choose the IP Set Info softkey. Verify that the IP addresses are correct (note that if no router is used, the router will be set to the same IP address as the LAN 1 address). 3. Verify that you can communicate to the analyzer via all external connections that are defined (e.g. GCP, Modbus, I/O). Verify that network broadcasts are received correctly. 4. Put the analyzer back in Run and verify that all other operations are working as expected. CIM Door Upgrade Page 36 IP-0021

37 Appendix 1: Troubleshooting Tips This appendix provides the user with several possible faults that could occur with the installation of the new door, along with possible causes. Symptom Possible Causes Possible Corrective Action CIM Display will not come up. CIM Display will not connect to analyzer. Depending on the failure this may be due to faulty or incorrectly installed hardware. 1. Analyzer is not connected correctly or faulty. 2. Analyzer is not active 3. IP Addresses on the SYSCON are incorrect. Check that the CIM CAC3 board is properly seated, that the power connections are properly made, and that all other cable connections are correct. 1. Verify that the Ethernet cable is connected correctly as described in the procedure. 2. Verify that the SYSCON is running correctly by checking the LEDs on the board (refer to the Installation Manual for the SYSCON) 3. Try resetting the CIM using the reset button on that board. 4. There is a Connect to Debug option on the connection screen. This will allow the user to see the output of the Debug port of the SYSCON. CIM Display connects to analyzer but time does not update. No communication to analyzer on network Partial or incorrect communication on network Purge LEDs or alarm not functioning correctly. Database is not operating correctly, possibly because the upgrade to version 4.40 did not complete successfully. 1. Ethernet cable from CIM to ESB not plugged in correctly or is faulty. 2. IP address for the CIM not set correctly The database IP configuration file was not up updated or is incorrect. New purge cable not connected correctly or is faulty. Contact Customer Support for assistance. Verify that the database is at the correct version. Contact Customer Support for assistance. 1. Verify the Ethernet cable is connected correctly as described in the procedure. 2. Using the CIM display, verify the external IP settings are the same as prior to replacing the door. Try resetting the analyzer. Verify that the upgrade step at the end of the procedure was completed correctly. This step sets the database to correctly deal with the internal SYSCON IP settings. Contact Customer Support for assistance. Verify cable is connected correctly at all three locations: PECM, CIM, and SYSCON. Note that both the CIM and SYSCON ends are identical and should be interchangeable. The lead connecting to the SYSCON controls the purge alarm in software. The lead connecting to the CIM controls the purge alarm LED on the door. CIM Door Upgrade Page 37 IP-0021

38 Appendix 2: Fallback This appendix covers the basic procedure to fall back to the original Maxum door if the new CIM door is not functioning correctly. If possible the user should first try to troubleshoot the new door before resorting to reinstalling the original door. It is advisable that Siemens support be contacted prior to fallback. Step 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. Note: Note: Fallback involves removing the new CIM door and reinstalling the original door. This does not cover downgrading the software release of the analyzer or the workstation software. The beginning state of the analyzer will depend on the specific problem seen and whether the replacement procedure was completed. For this reason, some steps below may not be applicable. If assistance is needed, it is advisable that Siemens support be contacted prior to fallback. 1. Using appropriate safety precautions, power down the analyzer. 2. Open the door and disconnect all cables from the CIM door. This includes the following: 1. The power cable running to the CIM should be removed. 2. Intrinsic Safety and chassis ground wires running to the door should be disconnected at both ends. 3. Both of the Ethernet cables connecting to the CIM door should be disconnected at both ends. 4. Y shaped purge cable should be disconnected completely. 5. Cable running from SYSCON debug connector should be disconnected. 3. Remove the CIM door and reinstall original door. 4. Reinstall the following original cables: 1. HMI to SYSCON cage cable. 2. All previously installed ground wires associated with the door or HMI.. 3. The original purge cable from the PECM to the SYSCON DO NOT reconnect the original Ethernet cable to the SYSCON at this time. This will be done after IP addresses are corrected. CIM Door Upgrade Page 38 IP-0021

39 Step Note: In the following steps the IP settings for the SYSCON are changed back to the original settings. This is required if the original step to modify SYSCON IP settings was executed, even if the display appears to show correct settings. The method for doing this will depend on how far the installation of the door had progressed before deciding to fall back. In particular, if the step to modify database scripts (refer to page 35) has not been attempted, then it will be possible to modify IP settings using the HMI. If that step has been attempted (even if it may not have completed), then it will be necessary to use the bootloader menu on the SYSCON debug port to change the IP settings (changing using the HMI will appear to take new settings, but the settings will not actually be updated). Connecting to the debug port on the SYSCON requires a computer running a terminal communication program such as Hyperterminal. Only qualified users should attempt this without assistance. Contact Siemens support for more information if assistance is needed. 5. Apply power to the analyzer. The boot sequence should appear on the HMI. 6. (Important: If the step to modify database scripts as seen on page 35 has been attempted, then do not use this step. IP settings will have to be set using the bootloader accessible from the Debug port. Contact Siemens assistance for more information.) After the boot process is finished and the menu appears, it will be necessary to change the IP settings on the SYSCON back to their original settings. From the HMI choose the System Setup menu item on the Configure menu. Then choose the IP SET INFO softkey. Use the Modify softkey to change the IP address, IP gateway, and subnet mask back to the original settings. 7. Now that the IP settings for the CIM are correct, plug the original Ethernet cable back into the SYSCON. 8. Reboot the analyzer and allow it to come up. CIM Door Upgrade Page 39 IP-0021

40 Step 9. At this point it is necessary for the user to update the SYSCON so that the database can correctly operate with the IP settings being changed back to the original configuration. 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, the upgrade window is displayed. Choose the Show Details button. The window should be displayed as described previously in the procedure (refer to page 35). Uncheck all items except for Convert Existing Database and Database Scripts. Then click OK. The upgrade window should appear. Monitor the status and verify the process completes successfully. 10. Verify that the purge alarm LED and all other LEDs work as expected. 11. Verify that the Maintenance Panel display works as expected. 12. Verify that you can communicate to the analyzer via all external connections (e.g. GCP, Modbus). Verify that network broadcasts are received correctly. 13. Put the analyzer back in Run and verify that all other operations are working as expected. CIM Door Upgrade Page 40 IP-0021

41 Appendix 3: CIM Display Panel Operation Overview CIM Display Panel Operation Introduction This appendix is adapted from the Maxum Maintenance Manual section describing the use of the CIM Display. This chapter is intended for operating and maintenance personnel. All of the Maxum II s operational and daily routine maintenance tasks can be performed from the CIM color touch screen display. The CIM Display is the physical hardware that is installed in the door of the Maxum II. It is controlled by a processor board called the CIM Board. The combination of board and display is referred to as the CIM (Control Interface Module). The CIM runs an enhanced version of the HMI software that is used to control the Maintenance Panel originally equipped in the Maxum. Because this chapter deals primarily with the operation of the software, the term HMI may be used at times to refer to the software even though the hardware is the CIM or CIM Display. In addition, the display emulator in the workstation software is referred to as the HMI emulator. The HMI software on the CIM utilizes interactive display screens, menus, and icons for common functions. In addition, the software is equipped with context sensitive help for most functions. This makes the device intuitive and simple to use once the user is familiar with the basic operation. Emulator A PC-based graphical simulation of the physical CIM Display, known as the HMI emulator, is available using the PC based workstation software. This emulator is capable of performing all of the functions that are available with the physical unit. The emulator is a graphical representation of the physical display. Because of this, some aspects of the emulator appear slightly different than they appear on the physical unit. Older versions of the HMI emulator were designed to function like the original Maintenance Panel. When the newest versions of the System Manager and Gas Chromatograph Portal software are installed to support the CIM Display, the emulator software will also be updated to function in a similar manner to the CIM Display. CIM Door Upgrade 41 IP-0020 SYSCON2

42 CIM Door Upgrade 42 IP-0020 SYSCON2

43 CIM Display Hardware Overview The CIM display contains a back-lit color graphic display screen layered with a touch screen sensor. It is part of the Control Interface Module (CIM) assembly that includes the display, the CIM-BASE board, and the Communication and Control (CAC3) board (which is mounted on the CIM-BASE). Figure 3-1: CIM Display Status LEDs The four LEDs next to the screen indicate the analyzer system status and work the same as for the original Maintenance Panel. These LEDs are physically attached to the color display, although they are controlled by a separate control cable from the CIM Board. Green Power LED Yellow Warning LED Red Fault LED Red Purge LED The green "Power" LED lights when the power supply is on. The yellow "Warning" LED lights when the "Maintenance request" status signal is active. The red "Fault" LED lights when the "Failure" status signal is active. The red "Purge" LED lights when purge pressure is lost as detected by the PECM. CIM Door Upgrade 43 IP-0020 SYSCON2

44 Screen Characteristics Description The screen is in color and back-lit for easy reading. The interface is designed to function in a similar manner to the original Maintenance Panel, but easier to use and with added features. It is divided into several functional areas: Main Navigation Bar Status Bar Content Area Toolbar Softkey Bar Figure 3-2: Screen Layout Main Navigation Bar The main navigation bar is an added feature in the CIM display. It allows the user to return to the home menu screen, go back to a previous menu screen, or launch the interactive help function (all denoted by easy to understand icons). The help function on the main navigation bar is an interactive feature that provides context sensitive assistance. It is accessed by clicking the help icon on the far upper right and then clicking the area of the screen for which help is desired. When the feature is used a small pop-up window appears with help text relating to that area of the screen. The main navigation bar also contains information regarding the current level of password access (default is configure ). This information is located next to the help icon in the far right side of the bar. CIM Door Upgrade 44 IP-0020 SYSCON2

45 Screen Characteristics, Continued Status Bar The status bar shows various data about the analyzer, including the name, date and time, and run/hold status. It also shows information about the current application, stream, method, and cycle clock. In addition, the status bar contains gray buttons that permit the user to change the run/hold status or to select the current analyzer, stream, application, and method. Content Area The middle part of the screen is the general content area. It contains menu lists or parameters with the applicable values, as well as alarm messages and operator hints. The content area is where the primary information for a selected screen is displayed. The top left of the content area is usually a general name or description of the screen. Toolbar The toolbar is an added feature in the CIM display. It allows the user to navigate directly to commonly used screens. This includes access to the alarm screen as well as settings for valves, temperature, pressure and streams. It also allows the user to easily navigate to the different menu levels (monitor, maintenance, and configure). The Softkey Bar The softkey bar appears at the lower edge of the screen. Its gray background distinguishes it from the content area. The softkey bar associates different actions with the softkeys located below the screen. The actions vary depending on the screen shown. No Numerical Keypad The original Maintenance Panel equipped with the Maxum had a numerical keypad that was used for data entry. The CIM display has been designed so that this keypad is not necessary. Menu items can be selected just by tapping the screen. When numerical entry of data is needed, a small pop-up keypad window will be displayed. Elimination of the numerical keypad allows the CIM display to have a much larger readable content area with only a slightly larger panel. CIM Door Upgrade 45 IP-0020 SYSCON2

46 Using the CIM Display Navigating the Menus Just like the original Maintenance Panel, the menu tree of the CIM Display is organized into three functional levels. This structure is used to allow different levels of access to analyzer control and configuration operations. The three functional menu levels are as follows. Monitor Menu This menu level allows minimal control of the analyzer and viewing of analyzer status and is intended for operations personnel. All password levels have access to the Monitor Menu; however, higher access is necessary for some functions. Maintenance Menu This menu level allows detailed application and stream control and is intended for engineering personnel. A password with Maintain level access is needed to access the Maintenance Menu and all of its functions. Configure Menu This menu level allows system configuration control and is intended for use of system administrators and engineers. A password with Configure level access is needed to access the Maintenance Menu. Higher ( Super ) access is needed to access user and password functions. These different menu levels can be selected using the tool bar icons. The three options show up any time one of the main three menus is displayed. Select the Home icon in the far upper right corner of the CIM Display in order to display the default menu, which will display the menu icons. The Toolbar The Softkey Bar The toolbar is a new feature created for the CIM display that allows the user to navigate directly to commonly used screens. In addition to selections described above, this includes access to the alarm screen as well as settings for valves, temperature, pressure and streams. To navigate to a screen using the toolbar, simply tap on the desired icon (or click if using the software emulator). At the bottom of the screen, below the content area, is the softkey bar. The softkey bar functions just as it did in the original Maintenance Panel. When a menu is displayed, a series of softkeys appears on the softkey bar. As the user navigates through the different screens, the softkeys that appear will depend on the particular screen being displayed. The function of each softkey is identified by a label on the softkey. You may also see more information about the function of the softkey by using the interactive help feature. Refer to Accessing Help later in this section. To operate a softkey, simply touch it on the display screen (or click on it if using the HMI emulator). CIM Door Upgrade 46 IP-0020 SYSCON2

47 Using the CIM Display, Continued Entry of Data The original Maintenance Panel for Maxum was equipped with a numeric keypad for data entry. The touch screen function of the CIM Display eliminates the need for this. When data entry is required on the physical CIM Display, a pop-up window with numeric keypad appears on the screen as shown below. Figure 3-3: Window for Data Entry on CIM Display When the HMI emulator is used, the data entry window does not appear because the numeric keys on the computer keyboard can be used. CIM Door Upgrade 47 IP-0020 SYSCON2

48 Using the CIM Display, Continued Accessing Help Context Sensitive Screen Help The online help function of the CIM Display represents a large leap forward in usability over the original HMI. It allows the user to obtain a help description for virtually element displayed on the screen. It also allows the user to obtain detailed descriptions of alarms as well as possible causes and suggested corrective actions. To access help touch the help icon ( ) on the upper right corner of the CIM display (or click on the icon if using the emulator). This puts the software in an interactive help mode. This mode is denoted by the background for the help icon changing color. The help mode is context sensitive. This means that for the next item you touch (or click), the software will display a help window for that item. In the figure below, the help icon was selected and then the Temp icon on the toolbar. This displayed the help text window in the middle of the screen. Figure 3-4: Window for Data Entry on CIM Display Click OK to remove the window and continue. Note that once the window is removed, the software is no longer in the help mode. Clicking a selection will have the normal effect. CIM Door Upgrade 48 IP-0020 SYSCON2

49 Using the CIM Display, Continued Alarm Help One useful feature of the online help function of the CIM display is the ability to get detailed descriptions of alarms as well as possible causes and suggested corrective actions. To access alarm help, first load the alarm screen by selecting it from the menu or from the toolbar on the right side of the screen. Next, touch the help icon ( ) on the upper right corner of the CIM display (or click on the icon if using the emulator). This puts the software in the interactive help mode. The background of the help icon will change color when in interactive help mode. To see help for an alarm, click the Description field for that alarm while in interactive help mode. This will display the alarm help screen. In the figure below, the help icon was selected and then the Description field for the first alarm on the list. This displayed the help text window in the middle of the screen. Figure 3-4: Window for Data Entry on CIM Display Note that this help box is displayed only when the Description field is selected while in help mode. Selecting other fields for the alarm provides help information describing what the field is used for (context sensitive help described on the previous page), rather than information about the alarm. CIM Door Upgrade 49 IP-0020 SYSCON2

50 Password Restrictions Description It is possible to configure the CIM Display for different levels of password access. By default, six different levels of password access are available. By default, the display is set for a configure level of access, which allows the user to perform almost all analyzer functions except password administration. If the access level of the current active password is not sufficient for a requested operation, a screen will appear stating that the required level of password must be entered. By default, when a password is entered, the session remains active for 30 minutes unless a different time period has been set; see description of SET TIME softkey below. Checking Your Access To see if you are authorized to perform a specific function, use the appropriate menu path to navigate to that function. If the following screen appears, then password entry is necessary to perform that function (i.e. the current level of access is not sufficient to perform the function). Select the LOGIN softkey and then enter the appropriate password and press OK. If the password is correct and has sufficient access, access level will change (seen in the upper right corner of the display next to the help icon). You are now logged on and can execute the required function. If the password is incorrect, the screen will revert back to the home menu and the access level will not change. Password Format A password consists of one to six numerical digits and is entered via the numeric keypad. CIM Door Upgrade 50 IP-0020 SYSCON2

51 Password Restrictions, Continued Obtaining/Changing a Password Passwords can be modified from the User s Passwords screen on the Configure menu. To change a password you must be logged on with Super level access. To change a password, select the table entry for the user and then tap (click) the SELECT softkey. This will display a window to modify the password. Privilege If your password is accepted you can modify any menu items or parameters assigned to your user level (or lower user levels). There are six predefined user levels (levels 0-4 and 99). The items that can be modified at these user levels are predefined and cannot be changed by the user. By default six users are defined. These are public, operate, calibrate, maintain, configure, and super. The default access level for each of these users matches their names. In addition, multiple individual users may be defined. These users must have unique names and they can be created with either operate, calibrate, maintain, or configure access levels. Creation and deletion of users must be performed using the workstation software. (Refer to the System Manager chapter of this manual for instructions on creating and deleting users). The change privilege remains in effect if the user presses any key before the timeout limit (default 60 minutes). In this manner the user does not have to re-enter a password repeatedly while browsing through menu screens. However, the analyzer automatically logs out (back to the default user), if the user has not pressed a key within the timeout limit. CIM Door Upgrade 51 IP-0020 SYSCON2