Technical Support Information No. 84 Revision 2.0 November 2004

Transcription

1 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 1 of 19 SYSCON Konstruktions-Verbesserung Zusammenfassung Als Teil unserer gegenwärtigen Tätigkeit den Maxum II zu optimieren, wird nun ein neues System Controller Modul gefertigt. Mit dieser Änderung sind wir in der Lage eingegangene Vorschläge zu realisieren und die Ersatzteil-Kosten für unsere Kunden zu reduzieren. Eine Übersicht zum Funktionsumfang des neuen SYSCON+ und der in Verwendung findenden Speichermodule wird präsentiert und erläutert. SYSCON Design Enhancement As part of the Product Continuous Improvement Plan, Siemens Applied Automation regularly makes improvements to Maxum software and hardware. Since the introduction of the Maxum edition II in January 2000, several electronic components and systems have been changed. As part of our on-going work to improve Maxum II, an all new System Controller Module is already in production. With this change, we are able to simplify our spare parts recommendations and reduce the cost of spare parts for our customers. We are discontinuing the entire SYSCON Module as a recommended spare part. The two versions of the original SYSCON (standard SYSCON Module, and SYSCON Module with extra memory, ) are now replaced as recommended spare parts by the single SYSCON+ Board Version 2 ( ) or SYSCON+ Replacement Kit SRAM 16 ( ) and SYSCON+ Replacement Kit CF ( ). This documentation describes the changes that have been made to the System Controller (SYSCON) and memory since today. General Description The System Controller (SYSCON) is the primary control computer board in the Maxum GC, the NAU and the Advance Plus door assembly. It is a single board based on 32-bit microprocessor technology. Maxum s operating system and database reside in its memory. In addition to computer functions, the SYSCON also provides: Control of the Human Interface (MMI) maintenance panel Interface to the external Ethernet Network Control of the Sensor Near Electronics Controller Interface to physical input and output channels (DO s, AO s, RS-232 and RS-485 serial ports) Slots to install additional I/O boards for extra analog and digital inputs and outputs

2 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 2 of 19 SYSCON is used in the Maxum Gas Chromatograph (GC) and also in the Maxum Network Access Unit (NAU) and the Advance Plus door assembly used to upgrade older Optichrom Advance GCs. In these three different products, the SYSCON itself is identical except for its mechanical housing. In the GC, the SYSCON is installed in a large metal housing or cage that provides electronic shielding. This cage has changed in design since the original Maxum. The change is further described below. In the NAU or Advance Plus, the Maxum is mounted without a cage. Since the original release of Maxum, the SYSCON has been provided in a variety of different form. In the original Maxum, the board used a 486 class of microprocessor, certain kinds of memory and provided certain kinds of physical I/O capability. In the current version of Maxum, the board uses a newer and faster type microprocessor, uses newer kinds of memory and provides increase capability with its physical input and outputs. The original version is called SYSCON. The newer version is called SYSCON Plus or SYSCON+. A more detailed history of the changes made to this board is provided in a section below and a detailed description of each board part number is provided in the part number table below. SYSCON+ module mounted in the Maxum II SYSCON+ module with the tray open SYSCON Memory SYSCON provides all of the operating system and database application memory for the Maxum. All of the memory is provided in two physical implementations; these physical implementations are described next. Several types of memory are used; the types of memory and a description of the way in which the memory is used is provided further below. The memory is involved in the way the Maxum recovers from power failure or system resets. Two start up processes are defined: cold boot and warm boot. These processes are also described below.

3 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 3 of 19 Physical Implementation 1) Memory Modules In-line memory modules are used in Maxum. These are small boards which come in two sizes. One of the modules is about 1 cm wide and 6 cm long and the other is slightly larger. Both modules plug into special slots on the System Controller Board (SYSCON). There is one slot suitable for the smaller module and there are 2 slots suitable for the larger module. The smaller module provides DRAM. The purpose of this memory is described below. Currently, only one version of this module is available; it provides 32 Mbytes of DRAM. The larger module is provided in two versions. One provides FLASH and SRAM. There are 8 Mbytes of FLASH mounted on one side and 8 Mbytes of SRAM mounted on the other side. The other version of this larger module provides 16 bytes of PSRAM. The purpose of these memory types is described below. Both of these modules have changed since the original release of Maxum. The amount of memory mounted on the modules has increased. This is described below along with the description of purpose of the memory. 2) Compact FLASH. Compact FLASH memory (CF) is also used in Maxum. The purpose of this memory is described below. When this memory is used, it is supplied in a small card, about 1.5 cm square. Only one card is used; it is currently supplied with 64 Mbytes of memory. This card plugs into a special carrier location on special printed circuit board (called the I2C Board.) The I2C Board then plugs into a board slot on the SYSCON+. In addition, a cable is installed which connects from the CF carrier board to the SYSCON+. Types of Memory and Description of Purpose 1) DRAM (Dynamic Random Access Memory) DRAM is very fast memory used as working area by the microprocessor in normal operation. DRAM is used to store the instantaneous current version of the application, all temporary variables, all working memory, temporary copies of the chromatograms and analyzer data, temporary working variables for the tables and more. When power goes off, the contents of DRAM are lost. Therefore, other memory is used to provide long term storage of important information (This is described below). DRAM is supplied on the smaller inline memory module used in Maxum as described above. As also described above, there is room on the SYSCON for only a single DRAM module. In the very earliest versions of Maxum, 8 Mbytes of DRAM were supplied. Later, this was increased to 16 Mbytes. On current versions of Maxum, 32 Mbytes of DRAM are supplied on a single memory module:

4 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 4 of 19 SYSCON Memory, DRAM 32 Mbytes, ) PSRAM (Pseudo-Static Random Access Memory) In some of the newest applications done in Maxum, there is a need for more temporary, or working, memory than can be supplied on the DRAM module described above. This may be required when applications are large or complex. Examples include PINA, Simulated Distillation, multi-sample-point air monitors with extensive reporting and certain combinations of other applications. However, as noted above, SYSCON provides room for only a single DRAM module and, for technical reasons this is limited to 32 Mbytes. Therefore, to obtain additional high speed, temporary memory, PSRAM is used. This kind of memory actually functions simply as an extension of DRAM. PSRAM is supplied on one of the larger inline memory modules as described above. It plugs into one of the two slots available for this kind of module. PSRAM is the newest memory type used in Maxum. It only used when there is a CF memory card installed and never when a SRAM / FLASH module installed. This memory also is only used on SYSCON+ and version 4.1 or later software. 3) SRAM (Static Random Access Memory) Both of the memory types described above share a common benefit and a common problem: they are fast, but they are temporary. When power is removed, the memory contents are lost. Therefore, other types of memory are used for permanent storage and to enable Maxum to automatically resume operation during recovery from a power outage. The first memory of this type, used in the original versions of Maxum, is SRAM. This "semi-permanent" memory is fairly fast and it is also backed up with a battery. As Maxum operates, it continuously copies some information from its fast, temporary memory into SRAM. The information kept in SRAM is calibration data, current measurement results, all application and database tables and table structure, user-entered information, analyzer identification information, any Modbus or computer interface maps, other communication information and the like.

5 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 5 of 19 When Maxum starts up following a normal power failure or system restart, it launches itself using information that is stored in the SRAM. This allows for a more rapid restart and retention of the latest measurement information from the process. From a "cold boot" status, the first thing Maxum does is copy all of the contents of FLASH into a matching section of SRAM. Then, after that, the Maxum actually runs from the SRAM. Any time the human user changes any thing about the application or the database, or if the user recalibrates, the new information goes into SRAM. It also goes into FLASH - but only if the user does a "Save To Flash" instruction (in Version 4.1, there are certain automatic situations where Save To Flash occurs). 4) FLASH memory As described for SRAM, Maxum requires permanent memory to enable recovery from loss of power. SRAM normally provides this permanent memory. However, in any product that uses software, conditions can occur that cause the software to fail and generate errors. Because the Maxum keeps the SRAM continuously updated, it is possible that errors occurring in the software or failures of the microprocessor might cause corruption of the restart information image in the SRAM. While this situation is not a problem for personal computers and many other types of equipment, it is a potentially bad situation for a chromatograph. This is because the chromatograph must be able to come to a known hardware condition to protect itself from damage caused by measurement gases or other gases flowing in the chromatograph oven. Memory Expansion Module, 8Kbytes SRAM + 8Kbytes FLASH,

6 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 6 of 19 To prevent this possibility, the original versions of Maxum provided FLASH memory which is a permanent, alternate back up to the SRAM. This FLASH is permanent memory that retains its information, without batteries, even when the power of the system is off. However, it is relatively slow memory so it could not be used in continuous service. Therefore, FLASH is loaded only in certain automatic situations or at any time that it is manually commanded by the user. The manual procedure is called Save To FLASH. When the human user of Maxum commands Save To FLASH the Maxum copies an exact image of the current SRAM into the FLASH. This provided an area of safe memory. If Maxum ever had a condition in which the SRAM might have been corrupted, the Maxum would restart itself using the data image in the FLASH memory. (Please see also the discussion below regarding Warm Boot and Cold Boot. 5) CF (Compact FLASH.) In all newer versions of Maxum, a newer type of memory is used to replace SRAM and FLASH as described above. This newer CF memory format is similar to the memory used in digital cameras and MP3 players. It combines the speed of SRAM with the durability of FLASH. The newest versions of Maxum still retain the principle of a separate memory that is used for different start up situations. As described above, SRAM and FLASH provided these separate memory areas in the original versions of Maxum. With CF, the available memory is partitioned into different sections. One section is used for normal power fail recovery and the other section is used for emergency recovery if there has been a system fault. Maxum uses a 64 Mbyte version of the CF. When this is done, no SRAM / FLASH modules are used. However, a PSRAM module may be used to augment DRAM. Compact Flash Card, 64 Mbytes FLASH memory,

7 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 7 of 19 Start Up Processes: Warm Boot and Cold Boot When the Maxum starts up following a power failure or a reset from some other source, it begins by launching itself from memory images saved in non-volatile memory (such as SRAM, FLASH or CF but not DRAM or PSRAM.) Maxum keeps two copies of the memory it needs for starting up. One primary copy is routinely and continuously kept current; that means that any time there is a change in the results, calibration, operation or anything else, this primary copy of memory is updated by the microprocessor. In early Maxum versions, this primary start up image was kept in SRAM; in later versions it is kept in designation sector of CF. A normal start up situation is called a warm boot. This occurs following ordinary power outages occurring for any reason. In a warm boot situation, Maxum starts up from the primary copy of memory. The warm boot procedure runs rapidly and recovers the most recent status of Maxum typically the data and status that it had immediately before the power loss occurred. Maxum also keeps in memory a secondary copy of information needed to restart. This secondary image was kept in FLASH in the original versions of Maxum. In newer versions of Maxum, this secondary image is kept in a separately designated sector of CF. Unlike the primary image, which is updated continuously, the secondary image is updated only on certain occasions. It can be updated by manual command which occurs when the user implements a Save To FLASH. Additionally, there are certain automatic situations in which it is updated. Various conditions might cause Maxum to have an abnormal reset situation. These conditions include abrupt hardware failure, severe electrostatic or other electrical interference that disrupts the microprocessor, unusual software situations or failures or other unusual occurrences.

8 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 8 of 19 An abnormal start up situation is called a cold boot. In this case, Maxum assumes that some previous failure has caused corruption of the primary memory area. Therefore, Maxum restarts from its secondary memory area which has been carefully protected. This start up procedure runs a little more slowly. Additionally, the restart condition of Maxum will not be exactly the same as the condition it was in before the restart occurred; instead, it will be the condition Maxum was in at the time of the last Save To FLASH command. If Save To FLASH has not been done recently, this could be a very old or out-of-date condition. This fact explains the need for a maintenance procedure. If Maxum restarts from a very old condition, it is possible that Maxum may be badly out of calibration or may have lost current process information or may have other errors that could result in longer downtime. To prevent this, the user should ensure that Maxum regularly updates its secondary memory with a Save To FLASH command. This should be done manually whenever any kind of manual maintenance is performed on Maxum. In addition, Maxum can be configured to do this automatically following calibration and at certain time intervals during the day. SYSCON Change History The version of the System Controller (SYSCON) used in current versions of Maxum is referred to as SYSCON Plus or SYSCON+. The version shipped in original Maxums was referred to only as SYSCON. The current version of SYSCON+ is, in all cases, correct for use as the spare part for all previous versions of SYSCON. This is true for original Maxum or Maxum II of any age as well as NAU and Advance Plus door assembly. For a detailed explanation by part number, please see the SYSCON and SYSCON+ Part Number Table below.

9 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 9 of 19 The SYSCON+ offers several improvements over the original SYSCON. The following table summarizes the differences: Feature SYSCON SYSCON+ Microprocessor 486 class: 66MHz 586 class: 133 MHz Supported Memory (Originally, Optionally and Currently Supplied Memory) DRAM: Up to 32Mb (originally 8, then 16, last 32Mb) DRAM: Up to 32Mb (32Mb) (Note: CF and PSRAM require software version 4.1 or later.) SRAM: Up to 16Mb (originally 4, then 8; optional 16Mb) FLASH: Up to 16Mb (originally 4, then 8; optional 16Mb) SRAM: Up to 16Mb (originally 8MB with optional 16Mb; current- none supplied) FLASH: Up to 16Mb (originally 8MB with optional 16Mb; current- none supplied) CF: >256Mb (originally none supplied; current 64Mb) PSRAM: >32Mb (originally none supplied; current option 16Mb) Used in GC or NAU or Advance Plus All All Housing cage Supplied with Cage for GC Supplied without Cage for NAU Supplied without cage. Mounts in original SYSCON cage or newer Maxum II cage Built-in Ethernet ports 1 typically used to connect to external network; 2 Extra Ethernet ports by Network Interface Controller (NIC) board 1 NIC board installed to supply 2 nd port for internal system Separate NIC board not used. I 2 C board to house CF memory plugged into same slot. Built-in I/O and capacity 2 AO (4-20ma) 4 DI (contact sense) 4 DO (1 amp capacity) 1 RS RS AO (4-20ma) 4 DI (contact sense) 4 DO (2 amp capacity) 1 RS RS-485 I/O expansion card slots 2 2

10 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 10 of 19 The change from SYSCON to SYSCON+ occurred in several steps. The steps and a brief explanation of the change is described in the following table: Part Number (Chronological order) Description Reason for Change DISCONTINUED PARTS Custom SYSCON in cage for GC Same with extra memory SYSCON without cage for NAU Same with extra memory Original design Original design SYSCON+, Version 1; with error in Digital Output design. Polarity reversed from original SYSCON Same as above; included cross-over cables to compensate for DO design error. Did not include other adapter cables needed for easy field replacement of SYSCON. Introduce new features of SYSCON+ Introduce new features of SYSCON+ but correct for design error SYSCON+, Version 1; with miscellaneous cables for easy field replacement of SYSCON. But did not include cross over cables to compensate for DO design error. Introduce new features of SYSCON+ but enable easy field upgrades. CURRENT PARTS SYSCON+, Version 2; with DRAM only. Introduce new features of SYSCON+ but with fully updated design. Allow re-use of existing cables and memory to minimize cost of spare parts alone Replacement for most previous versions; includes SRAM and FLASH Same with extra SRAM and FLASH; therefore can replace ALL previous versions Same except with CF memory and no SRAM or FLASH; therefore replaces ALL previous versions running Version 4.1 or later software (except on Advance Plus) Kits of multiple parts including adapter cables and memory. Assembled to enable: new features of SYSCON+ with very easy field upgrade and fully updated design.

11 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 11 of 19 SYSCON and SYSCON+ Part Number Table All relevant parts are described individually below: Part No. Description (SYSCON p/n Table) Status Comments DRAM Memory expansion module 32 Mbytes Dynamic RAM (DRAM) (Note: Part is also sold at a special low price if sold in conjunction with a Software License Maintenance Agreement.) Active Compact Flash card 64 Mbytes Flash memory Active IDE attachment cable Used to connect the SYSCON+ to the I2C board (p/n ) which is carrying a Compact Flash memory module. Active SYSCON; used in Maxum 1 and beginning production of Maxum II. Original SYSCON board Pre-mounted in original SYSCON cage assembly Memory: 32 Mbytes DRAM; 8 Mbytes SRAM; 8 Mbytes SRAM (single SRAM module) Pre-programmed with current version of Maxum software Discontinued Default universal replacement is Preferred replacement if this part is not used in Advance Plus is

12 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 12 of Same as ) except: Memory: 16 Mbytes SRAM and 16 Mbytes Flash (2 each SRAM modules) Discontinued Default universal replacement is plus Preferred replacement if this part is not used in Advance Plus is custom (see note) SYSCON; used in NAU or Advance Plus Did NOT include cage assembly (as was used for SYSCON in the GC) Memory: 8 Mbytes SRAM; 8 Mbytes Flash (single SRAM module) (Note, this item was also sometimes built with 16 Mbytes SRAM and 16 Mbytes Flash (two each SRAM modules) to accommodate needs of the Modbus memory map; however, this change was made by custom request only.) Discontinued Default universal replacement is plus Preferred replacement if this part is not used in Advance Plus is Pre-programmed with current version of Maxum software

13 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 13 of and SYSCON Replacement Kit (SRAM 16) 1 ea SYSCON + with 32 Mbytes DRAM 1 ea SYSCON+ Purge connect for Maxum 1 1 ea SYSCON+ Purge connect cable for Advance Plus 1 ea Power cable for Fiber Optic Converter 1 ea SRAM Modules (16 Mbytes SRAM and 16 Mbytes Flash) (included with ) 1 ea. Labor Pre-programmed with current Maxum Software Version 1 ea SRAM Modules (16 Mbytes SRAM and 16 Mbytes Flash) (which must be ordered separately as described here) Active Use this on any NAU or on any Maxum GC which is running Modbus. Customer may also consider using Item 12 (above) for lower cost now. Customer may also consider using Item 15 (below) for best compatibility in the future and lowest cost in the future. These two parts together make a kit which is intended as a replacement for ANY configuration of Maxum 1, Maxum 2, NAU or Advance Plus. It is the most expensive SYSCON replacement option, however it is universal and its total price is comparable to the price of the items it replaces. This is the default spare part version if the customer does not know which replacement part he needs. If the customer is using a different version of software than the version currently shipping, this board can be upgraded or downgraded in the field. When running Software Version 4.1 or later and using Compact Flash memory, this board is also capable of using PSRAM memory expansion modules if needed for large, memory intensive applications. (See p/n ) Before purchase of this part, the customer should consider purchase of p/n (SYSCON CF). This newer part will only run with Software versions 4.1 or later. However, it allows significant reduction in spare parts cost because it uses less expensive CF memory. The lower price of the newer combination may justify simultaneous purchase of a Software License Maintenance Agreement if needed to upgrade current software to the latest version.

14 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 14 of SYSCON Replacement Kit (SRAM 8) 1 ea SYSCON + with 32 Mbytes DRAM 1 ea SYSCON+ Purge connect for Maxum 1 1 ea SYSCON+ Purge connect cable for Advance Plus 1 ea Power cable for Fiber Optic Converter 1 ea SRAM Modules (8 Mbytes SRAM and 8 Mbytes Flash) 1 ea. Labor Pre-programmed with current Maxum Software Version. These two parts together make a kit which is intended as a replacement for many configurations of Maxum 1, Maxum 2 or Advance Plus. It can not be used alone as the replacement option for NAUs which are supporting Modbus or for any Maxum gas chromatograph supporting direct Modbus outputs. In those cases, additional memory, p/n SYSCON SRAM 16 is also required. For additional information, please see the description of p/n plus elsewhere in this document. If the customer is using a different version of software than the current version, this board can be upgraded or downgraded in the field. Active Use this on any Maxum GC which is not running Modbus. Customer may also consider using Item 12 (above) for lower cost now. Customer may also consider using Item 15 (below) for best compatibility in the future and lowest cost in the future. When running Software Version 4.1 or later and using Compact Flash memory, this board is also capable of using PSRAM memory expansion modules if needed for large, memory intensive applications. (See p/n ) Before purchase of this part, the customer should consider purchase of p/n (SYSCON CF). This newer part will only run with Software versions 4.1 or later. However, it allows significant reduction in spare parts cost because it uses less expensive CF memory. The lower price of the newer combination may justify simultaneous purchase of a Software License Maintenance Agreement if needed to upgrade current software to the latest version.

15 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 15 of SYSCON+ (Version 1); used for GC Includes SYSCON Spare Parts Kit: includes cables SYSCON+ Purge connect for Maxum SYSCON+ Purge connect cable for Advance Plus Power cable for Fiber Optic Converter (Note, this item was intended to be a universal SYSCON replacement kit where the SYSCON+ Version 1 is replacing the original SYSCON. As also described for p/n , this kit was sold without the cage assembly used in the GC. The cables included with this kit were intended to make replacement in the older Maxum 1 and the Advance Plus door assembly easier.) (Note, this kit did NOT include the Digital Output crossover cables described in kit p/n above. Therefore, this kit is not useful in the field. There were some design errors in the definition of these two kits with the result that both parts kits are incomplete.) Discontinued Default universal replacement is plus Preferred replacement if this part is not used in Advance Plus is SRAM Memory expansion module 8 Mbytes Static RAM with battery back up (SRAM) and 8 Mbytes Flash (Note: Part is also sold at a special low price if sold in conjunction with a Software License Maintenance Agreement.) Active

16 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 16 of SYSCON+ (Version 1); used for GC, NAU and Advance Plus. First release of the SYSCON + board Does NOT include cage assembly (Note: This board was released about the same time as the new-style of cage assembly used in Maxum II. When this SYSCON is used as the replacement part in a GC, the customer is expected to disassemble the cage assembly in order to get access to the board. This is somewhat difficult with the original cage used in the GC but is fairly easy with the newer cage design. Additionally, the NAU does need to have a cage at all.) Memory: 32 Mbytes DRAM; 8 Mbytes SRAM and 8 Mbytes Flash (single SRAM module) (Note: This board is also capable of functioning with Compact Flash (CF) instead of SRAM modules. The CF is mounted on a separate board which plugs into one of the slots on the SYSCON board. However this requires software Version 4.1 or later software. This item was never sold in this configuration, but it is possible to upgrade to this configuration in the field.) Discontinued Default universal replacement is plus Preferred replacement if this part is not used in Advance Plus is Pre-programmed with current version of Maxum software REVERSED (!) polarity of Digital Outputs (Note: Although this board was intended to replace the original SYSCON, a design error had the field wiring for the Digital Output channels reversed. Normally Open was connected to Normally Closed and vice-versa. For additional information, please see descriptions for p/n and )

17 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 17 of Same as except: Configured as a Spare Parts Kit which includes Digital Output cross-over cables (p/n ) (Note: This item was created solely as a spare parts kit. The cross-over cables switched the polarity of the Digital Output channels back to the same state as the original SYSCON. The design of the board itself was later corrected and became SYSCON+ Version 2. For additional information, please see also the description on p/n ) Discontinued Default universal replacement is plus Preferred replacement if this part is not used in Advance Plus is I2C Controller Board (de-populated) Used to mount Compact Flash memory card onto SYSCON+ board, p/n Installs in the ISA board card slot on the SYSCON+ board, p/n (Note: a cable to connect this to SYSCON+ is also required; see p/n below.) (Note, this I2C Controller is also available in a populated version (p/n ) which will be used in future electronic configurations of Maxum.) Active

18 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 18 of SYSCON+ (Version 2) Revised version of SYSCON+ board; Digital Output polarity is corrected (for additional information, please see description about p/n ) Memory: 32 Mbytes DRAM Does not include SRAM or Compact Flash Does not include cage assembly Does not include software programming When running Software Version 4.1 or later and using Compact Flash memory, this board is also capable of using PSRAM memory expansion modules if needed for large, memory intensive applications. (See p/n ) This item is intended as a partial replacement for ANY configuration of Maxum 1, Maxum 2, NAU or Advance Plus. This item is the least expensive SYSCON replacement option; EXCEPT: the customer must retain the existing memory modules from the SYSCON being replaced and install them on this board before operating. This means the customer must move the existing SRAM module or Compact Flash card to this new part before operating it. Active PSRAM Memory expansion module 16 Mbytes of Pseudo-Static RAM (PSRAM) Mounts in a memory slots near the DRAM module; uses a slot formerly occupied by SRAM modules Provides expansion of high speed memory similar to DRAM This module is used ONLY on SYSCON+ with Version 4.1 or later software and ONLY when Compact Flash is also in use. Required primarily for memory intensive applications (example, PINA, air monitors, simulated distillation) Active

19 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 19 of SYSCON Replacement Kit (CF) 1 ea SYSCON + with 32 Mbytes DRAM 1 ea SYSCON+ Purge connect for Maxum 1 1 ea SYSCON+ Purge connect cable for Advance Plus 1 ea Power cable for Fiber Optic Converter 1 ea Compact Flash Module (64 Mbytes Flash) 1 ea I2C Controller Board (depopulated) 1 ea IDE attachment cable Active Use on any NAU or Maxum GC. Customer should always consider this part as the replacement for all other SYSCON versions. This is for best future compatibility and for lowest cost in the future. 1 ea. Labor Pre-programmed with current Maxum Software Version This item is intended as a replacement ONLY for configurations of Maxum 1, Maxum 2 or NAU that are running software Version 4.1 or later. When running Software Version 4.1 or later and using Compact Flash memory, this board is also capable of using PSRAM memory expansion modules if needed for large, memory intensive applications. (See p/n ) This item cannot be used on Advance Plus because the I2C controller board and Compact Flash memory card will not fit into available space This is a lower priced spare part version for customers with current version software. This item allows significant reduction in spare parts cost because it uses less expensive CF memory. Although this cannot be used with earlier software versions, the lower price of this newer combination may justify simultaneous purchase of a Software License Maintenance Agreement if needed to upgrade current software to the latest version. If the customer is using a different version of software than the current version, this board may be upgraded or downgraded in the field but it may not be downgraded lower than Version 4.1.

20 Maxum II - Syscon Module Design Enhancement As part of our on-going work to improve Maxum II, an all new System Controller Module is now in production. The housing of the new Syscon Module is fixed to the top of the Maxum II electronics enclosure. The Syscon+ Board is mounted on a slide out tray that functions as the front and the bottom of the Syscon Module housing. Two 5M nuts (5/16 or 8 mm wrench) hold the front of the slide out tray to the top of the housing. Remove these two nuts and pull the bottom tray forward and down. The tray will hang in the enclosure in the same manner as the original Syscon Module but with better access to the Syscon+ Board. The Syscon+ Board can be removed with the bottom tray in place or the tray can be removed from the analyzer prior to removing the Syscon+ Board from the bottom tray. The New Syscon Module Mounted in the Maxum II The primary change in this design enhancement was to eliminate the large mounting brackets on the Syscon Module. Without these brackets, the new Syscon Module is mounted flush with the back of the electronics enclosure and closer to the power supply. This change allows over an inch of additional space in the front of the Syscon Module, which allows more room for the I/O wiring and fiber optic cabling (when used), between the Syscon Module and the door. There is also more room between the Syscon Module and the Electronic Pressure Controllers (EPC), which allows better access to the upper right Solenoid Valve Control Module (SVCM). The Old Syscon Module - Maxum II There are some changes in the wire routing for the I/O, communication and power. The power connections for the Syscon have been moved to the bottom of the slide out tray. An opening has been added to the back of the module for the LAN 2 Ethernet cable and other wires. This new configuration will make it easier to troubleshoot the Syscon+ and associated electronics. When the bottom tray is in the open position the whole Syscon+ board is now visible. This gives the user easy access to the memory modules, cable connections and the printed circuit boards mounted in any one of the 5 expansion slots on the Syscon+. With this change, we are also able to simplify our spare parts recommendations and reduce the cost of spare parts for our customers. First, we are discontinuing the entire Syscon Module as a recommended spare part. The two versions of the original Syscon (standard Syscon Module, and Syscon Module with extra memory, ) are now replaced by the single Syscon+ Board ( ) or Syscon+ Replacement Kit ( ). Second, all of the many former types of Syscon spare parts, (Syscon, Syscon+, NAU, Advance + or Syscon Modules) are now replaced by the single part number, The New Syscon Module with the tray open August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 1 of 6

21 Syscon+ Board Removal (New Syscon Module) To remove the SYSCON+ board, from the SYSCON Module it is recommended, but not required, to first remove the slide out tray from the electronics enclosure. To reduce electrostatic damage, wearing a properly grounded wrist type ground strap is strongly recommended when handling electronic boards. To remove the Syscon+ slide out tray: 1. Open electronic enclosure door by pulling the left side of the latch out and turn the latch ¼ turn counterclockwise. Care should be taken to not place tension on the maintenance panel (MMI) interface ribbon cable when opening the door. 2. If expansion boards are installed in Syscon+ expansion slots, disconnect their interface cables. Identify and mark each expansion board interface cable as to its mounting location. 3. If SYSCON is connected to a network, disconnect the 10BaseT connector. 4. Disconnect all cable connectors from External Interface Cable Connector panel. 5. From rear left bottom of SYSCON, remove the two external PECM Power Cables. To remove cables, press in the connector locking tabs and pull connector outward. Each cable has its own unique connector to prevent connection errors. 6. Using a 8 mm (5/16) open-end wrench to remove the two 5M nuts located on the top front edge of the Syscon Module. This will allow the front and bottom tray to slide out of the sides of the Syscon Model cage. 7. Pull the slide out tray on the SYSCON assembly forward and down so it rests on the rubber mounting foot. 8. With all external wires disconnected from the slide out tray, lift the tray up and out of the track on the sides of the Syscon Module Assembly. External Interface Cables 5M Nuts Expansion Board Slots Power Cables 10BaseT Network Connection Rubber Mounting Foot Syscon+ Module Mounted in the Maxum II To remove the Syscon+ Board from the slide out tray: 1. Label all cables connected to the Syscon+, then disconnect all cable connectors connected to the Syscon Board. 2. Note slot location for each expansion board so they can be reinstalled in same slot. Then remove all of the expansion boards from the Syscon+ board. 3. Remove the six Allen screws securing the Syscon+ to the mounting standoffs. Screws are located in each corner and center of motherboard. 4. When removing Syscon+ board, lift by its sides. DO NOT touch board mounted components. Discharge of body static electricity can damage components. 5. Place Syscon+ Board in an anti-static bag for return to Siemens Applied Automation. 6. To reinstall motherboard, repeat steps in reverse order. Debug Serial Ports LAN2 Ethernet Additional Memory Slot Purge Syscon+ Standard Cable Connections MMI Power Reset Switch August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 2 of 6

22 Kit, Syscon Plus with Cables consist of the following parts Not all systems require the cables included in this kit. Replacement procedures for the Syscon board can be found in the Maxum Manuals, the Syscon Module is Chapter 4. SAA Part No. Description Connector PCBA, SYSCON CABLE, SYSCON PURGE, INSIDE, SYSCON+ J CABLE, SYSCON+ PURGE, ADVANCE PLUS J CABLE,PWR FOR FO CONV, SYSCON+ P ** CABLE, SYSCON + DO CORRECTION** X UI User Information Item 2 is only used on Maxum Analyzers using purge alarm. Item 3 is only used on Advance Plus Analyzers using purge alarm. Item 4 is only used on systems using the Ethernet Fiber Optic Converter ( ) which is powered from the Syscon Board. Syscon Plus Cable Installation Fiber Optic Converter Power Cable P Pin 1 Red, Pin 2 Black or Syscon Purge Cable J1302 Remove jumper before installing cable Fiber Optic Converter Power Cable Remove Fan Power Plug from Board socket, install red wire from cable into Pin 1 (spare outside slot) and black wire into Pin 2 (spare inside slot). Match new cable pin orientation with existing pin orientation. Reconnect Power Plug to board socket P2101. Fan Power Plug Fiber Optic Converter Power Cable Microprocessor Fan ** will be added to this kit when avalible August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 3 of 6

23 Installation Instructions: SYSCON+ DO CORRECTION CABLE** 1. Install the Syscon + PCBA, , as per the instructions in the manual. 2. Remove the orange wiring termination plug from the Syscon+ X04 header, if it is installed. 3. Install the Syscon+ DO Correction Cable, , by connecting the upper black connector on the cable to the black header on the Syscon+ labeled X Connect the orange wiring termination plug to the orange header on the cable. 5. Connect the Digital Output field wiring to the orange termination plug as needed. Connect the Syscon+ DO Correction Cable to the Syscon+ X04 header. Syscon+ Installed in the Maxum Syscon Module SYSCON + DO CRORRECTION CABLE mm (~8 inches) Note: The DO Correction cable is only required on the Digital Outputs of the Syscon+ X04 termination header. The lower termination header labeled X05 in the drawing does not require a crossover cable. Syscon boards with an orange colored termination header do not need the crossover cable. The termination header is the receptacle part of the connector that is permanently attached to the printed circuit board. The terminal plug is the removable part of the connector. Connect Orange Field Terminal Bloc k X04 Connect to Black Syscon Header REQUIRED FOR USE WITH SYSCON + EXCHANGES DIGITAL OUTPUT NO & NC LINES P1-3,P4-6, P7-9 & P10-12 August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 4 of 6

24 Syscon Plus Board The new Syscon Plus Board, SAA Part Number , has been released and incorporated in Maxum II products shipped today. It will replace the existing Syscon board, SAA part number New Features: The 1 amp Digital Output relays have been replaced with 2 amp relays. This extra current capacity will allow two standard sample system valves on a single Digital Output channel SYSCON + The tantalum capacitors have been upgraded to electrolytic capacitors to increase the reliability of the power supply circuits. The Syscon Plus has a second on-board Ethernet port for the LAN 2 connection to the Snecon. The Network Interface Card (NIC) is no longer needed to communicate with the Snecon(s). To make room for the extra circuits, the new design removes the second ISA card slot and replaces it with a Sub-Miniature-B (SMB) 10BASE2 connector. New LAN 2 Connector The NIC board can still be installed and used on the Syscon Plus without any additional setup. It will automatically disable the new connector when it detects the NIC board. It will communicate through the NIC board or the new connector, but not both at the same time. Using the new connector does require a new cable. In the Maxum use the straight connector cable SAA part number In the Advance Plus use the 90 degree connector cable The SMB connector is a push in connector. Simply push the cable connector down over the board receptacle and it will snap on. The 10Base2 communication cables are not included in the Syscon Plus Kit. Compatibility: The new board is backward compatible with the old Syscon board used in the Maxum I, Maxum II, Advance Plus and NAU. There are some cable changes that must be made to make the board fully backward compatible. Use the new Syscon Plus with cables kit, SAA part number when replacing an older Syscon board with the new board. The cable changes are as follows; 1. The pins are reversed on the Syscon Inside Purge cable connector in the Syscon Plus. Swapping the wires on the cable can be done in the field if needed. Production and spare parts will use a modified replacement cable. Maxum I and Maxum II use: Advance Plus use: August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 5 of 6

25 2. The Syscon Plus uses a microprocessor that requires a fan cooled heat sink. The fan uses the same connector as the Fiber Optic Converter board. These two devices can both be plugged into the same connector. The Fiber Optic power cable was modified so that it can be added to the fan power connector. Fiber Optic Converter Kit, SAA part number , will now include both the old and the new cables. The new cable is SAA part number The Syscon Plus and these three cables and are in the spare parts kit. SAA part number Kit, Syscon Plus with Cables. The kit includes instructions on how to use the cables and when the new cables are needed. This kit should be ordered when the Syscon Plus is used to replace an existing Syscon Board. DOWNGRADE SYSCON OS, DB, DM The Syscon Plus board is shipped with the current version of software. Users with systems running older versions of software can downgrade the Syscon Plus to the version they are using. The following procedure downgrades the Syscon from 4.0b to 3.x, where x is the version of software saved in Upgrade 3.x subdirectory of Workstation Advance System Manager PC software. Downgrading to versions 1.0 and 2.0 is possible but not recommended. Note: Bios does not need to be changed. If using Workstation 4.0 Tools do NOT download BIOS. This will cause the load to fail and will require using the debug port to complete the SYSCON downgrade process. 1. Go to: Advance Utilities>Tools>Syscon>Software Upgrade. 2. Select Anlz to upgrade 3. Login (default: super/555) 4. Select File: Upgrade3.x\osnau.cmd 5. Wait for download to complete. August 21, 2003 Tech Tip: Syscon+ Module Design Enhancement Page 6 of 6