Fault findinq &Trouble shooting in maxDNA control svstem

The visual aids and performance of the control system are the basis for faultlocation and troubleshooting.

The visual aids are the following :-

l.Status LEDs on the power supply convertor modules.2. Status LEDs on the l/O modules.3. Status LEDs on the DPU.4. Status LEDs on the network switches.5.System diagnostic pictures on the maxStation.

The information given by the above sources is explained below.

The performance or behaviour of the control system is also a source for -predicting the nature of fault.

D'AGNOSING FROM STATUS NDICATORS

l.Status LED on power supply convertor modules:-

The power supply convertor modules will each have three status LEDs withlabels 'input'

,'fault' and 'output'. When the input power is connected to themodule then the corresponding LED is on and green and ,similarly , when theoutput is being generated then the'output' LED will be on and green.The'Fault ' LED , in the centre, wil l l ight up in case of module failure.

2. Status LEDs on l/O modules: -

- On the front plate of all l/O modules at the lowest part is a green LED withlabel 'ACTIVE'. This will be steady ON when the module is powered up andthe DPU is communicating with it.

- lf the DPU is not communicating with it, then the LED will be blinkingON/OFF at a steady frequency. The reasons for this can be.

a. The DPU configuration is blank.b. The DPU outputs are frozen orc. The address set on the module is not matching that

maintained in the DPU configuration.

- On certain l/O modules there is another green LED on the front with label'FUSE'. This is located just above the 'ACTIVE' LED.

\-t

v

The 'FUSE' LED will be steadily on when the common fuse of the moduleis healthy, and the field supply (usually 24 V DC) is available through theback plane. Otherwise the LED will be off (dark). In such a case, check thefuse healthiness and ensure that the field supply is reaching the backplane at connector P14.

Refer figure below for a view of the front plate of a module'

3. Status LEDs on DPU modules: -

OveruiewAt various times the 9 status LEDs on the DPU front panel flash green, yellow,red or display no color to indicate the associated hardware's functional status.Discussions in the following sections explain what the color changes mayindicate under different DPU states.

The status LEDs are divided into the following sections:

Network Status LEDs (Located at the corner of each of the network ports)maxNET Network A health (The same applies for Network B LEDF

l\rlt

E I

a zE I T€ t

E t te t cE 'E C

r*r

c ! *et rcg l rE r e

et tlF t a

s t l

E r a

v

Green Yellow - steady Yellow -bl inkinq

off

The networkconnection isoperational.

On power-up, thenetwork "A" and "8"

LEDs start off blinkingyellow until the DPUhears communicationfrom another station inits domain. The LEDgoes solid yellow andthen to green.

Some Network Error.

Each device (DPUs andWorkstations) send messagesthat contain a list of all stationsfrom which it is currentlYreceiving messages. lf the DPUreceives messages from astation that does not rePortreceiving messages from it, theDPU il luminates the YellowLED. The problem may or maynot be this DPU.

DPUdoes nothearfrom anystation

DPU notOperationalor LED Bad

Backup LED (Located at the corner of the backup cable port)

Green Yellow Red offBackup NetworkOperational

Some Backupnetwork Failures

Communicationsnotestablished tobackup DPU

DPU notoperationalor LED Bad

IOM LED (Located at the lower part of the DPU front plate)

Green Yellow Red off

Operational IOM N/A IOM Failed /TimedoutReset Required

IOM notinitialized

lVr

rther fault investigation of l/O

t / O LED (Located at the lower part of the DPU front plate)

Green Yellow Red off

All configured l/Ocards are workingcorrectly.

Some configured l/Ocards are workingcorrectly, and atleastone is not.

No configured l/Ocards are workingcorrectly

No l/O cardsconfigured in thedatabase or IOMfailure OR l/O cardsare either taken offscan or placed intosimulate mode.

modules can be done. Refer 5.1.1 & 5.1.8 in a later part of this document'

CP LED (Located at the lower part of the DPU front plate)

Green Yellow Red offBlink Yellow / Green -Healthy Heartbeat

Solid Green- CPfailure.

Blink Yellow / Green -Healthy Heartbeat;

Solid Yellow (<20sec) -Loading, or saving thedatabase;Solid Yellow (>20sec) -CP failure.

Card Failure Gard Failure

a

STATE LED (Located at the lower part of the DPU front plate)

4. Status LEDs on the network switches :-

The network switch (usually with 24 ports) has LEDs on its front for indicatingstatus of its operations.i) Power supply availability : LED labelled as SYST. This must be steady

green. lf switch is faulty, then a few seconds after power up this LED doesnot become green and instead becomes amber.

ii) By default the LED labelled as STAT will be lighted green.iii) For each port , the port status LED above it will behave as per table below

provided the switch is in STAT mode

\tt

DPU States Active DPU State/LED lnactive DPU State/LEDStandalone DPUs Green Yellow

Backup Warming Blinking Green/Red Blinking Yellow/Red

Hot Backup Blinking Green/Yellow Blinking Yellow/Off

Backup Enabled / No BackupAvailable

Blinking Green/Off Red N/A

Booting Red Red

Offline Off then Blinking Red Off then Blinking Red

Port status LEDcolour

Meaning

OFF No l inkSOLID GREEN Link presentFLASHING GREEN Port is sendinq or receivinq dataGREEN/AMBER Link faults present like error frames, CRC errors, etc.SOLID AMBER Port not forwarding due to being disabled, address

violation. etc.

D'AGNOSING FROM OPERATOR DISPLAYS ON MAXSTATION

o

5. System diagnostic pictures on the maxStation :-

From a single maxStation (be it Operator Work Station or EngineeringWork Station) theltate of each DPU in various control panels and the state ofthe network connections of the full system can be observed.

Viewing the DPU4F Status disPlaY

Through the SYSTEM STATUS main menu ,the DPU4F STATUS picture

can be accesled. In this display ,option is given to click and navigate to a displayof the status of any DPU which needs to be observed in detail.

The DPU4F Status display shows a collection of objects called annunciators.View this display to see a summary of the health of each of the maxDPtts in your

system. Each maxDPU is represented by an annunciator that contains color-coded icons for:

CP - (maxDPU's Control Processor) status,BK - backup status,l/O - l/O subsystem status,A B - maxNET networks A and B status.

A colored outline is used to denote which maxDPU of the Pair is active. Aquick glance at the display can indicate if all is well with your DPUs or if attentionis reqrlired. To view additional information about DPU status, click on a specificDPU annunciator to access a separate maxDPU Details display for the selectedDPU. See "Viewing the maxDPU Details Display," later in this chapter.

The maxDPU Pair annunciator just has two of each icon, the upper rowfor the Primary DPU and the lower row for the Secondary DPU. To indicate theactive DPU, a cyan-colored border surrounds the row. lf the border is not visible,neither DPU is active (or the display cannot communicate with the DPU)'Eachrow or icon displays data as described in table below'

\t4

DPU Status good(Dark Green, ifDPU Fan and/orBattery bad)

DPU Statusmarginal(Dark Yellow, ifDPU Fan and/or

DPU Status bad(Dark Red, i f DPUFan and/orBattery bad)

SBPcommunicationsbad

SBPcommunicationsbad

Normal or Non-Critical l/O cardbad

SBPcommunicationsbad

Network has Failed( lf DARK-GREY:Network is OFF)

(t

5.1.0 Viewing the DPU4F Details DisplaysClick on a specific DPU annunciator, apfiearing !lt!:. DPU4F Status display' to

""""tt a DPU4F Details display for the selected DPU'

The DPU4F Details Display simulates a front maxDPU faceplate and

provides a list of DPU status detajls. When you select an annunciator object for a

specific DPU pair, animated faceplates "ppeat for primary and secondary DPUs'

iP

Refer drawing below for a view of the DPU4F Details picture as seen on

Understanding the DPU4F Faceplate| ' r l r f rn r : t f c r r rs r r rv r ! ! v v r -J a r rangement fOr an

TheDPU4Ffacep la te fea turesLEDsident ica | to theLt t^ r L ^ ^ ^ - ^ a i a f a r l

;:l'#t"ti. ii""il; colors on a DPu faceplate indicate the associatedn - ^ L - - ^ ^ n r r a l l ,

f,l.,.:ffi;tr^t,'i";' status. At various times the LEDs flash green' vellow' redr . . ^ ^ { i ^ n a l e f a f t t c

ft 61;;il;;-'i;inJicatethe-associated,hardwar::^l11tl:",:iL:t15;il:''rEilJ"ili,".;; ,ho*n on the disptay shoutd be identical to the color states

o

on the actual DPU.The significance of the LED colours is already described in point 3 on pages 2 to

4 above.

Data on DPU System display which is additional to the physical module faceplate

5.1.1 l/O Detail LEDsln addition to the l/o summary LED on the DPU front panel' the DPU4F Detail

display also contains four LEDs to indicate card status organized by typg of loM

operation. This is ,irit"l. to the inOicators on the DPU4E display. These LEDs are

located adjacent to the faceplate' The color

codes for the individual LEDs are tne same as for the l/o summary LED'listed

above(That is otr,neqverrow ano oreen and the significance is the same but

appficaOfe to the specific category given below)'

The l/O oPeration LEDs are:Fast Digitil Inputs (labeled Dl on.the display)

outputJ (label'ed AO/DO on the display)

lnputs (labeled Al on the disPlaY)Items (iabeled ITEM on the display)

click the l/o status button next to the maxDPU4F faceplate graphic to, access an !

l/O buffers inu"nto-ry rtatus displ"y. i"";tlO Status," later in this chapter' The

information on that dispray can exprain why an error condition is being indicated

by one of the l/O Status LEDs'

5.1.2 Time SYnc InformationTime Syncnronizaiion iniormation for the DPU is shown in two fields near the

bottom of the t"""pi"i". in" top fielo oisplays-either "Time Slave" or "Time

Master,, dependinJrpon no* tire OiU is configured. A Time Slave gets the

current date and time from a Time Master'

The tower field displays the lRlc-B;A1-tJ; of the DPU' lRlG-B is an international

standard tor a tim-Jtransmission tig-n"l.Jne inro-a signal is typically supplied by

a high accuracy,our." such as " 6ps receiver. The maxDPU4F may be

purchased witn an opltn to allowit io OecoOe the IRIGB signal' A DPU (or DPU

pair)with the IRG-B decoder will typically be used as a Time Master in the

;;;i;, other DPUs will be configured as Time Slaves'

On a Time Slave DPU, the lower OitpLV field will be.blank' On a Time Master

DpU, the tower nJO *irf contain IRi6;6trs information' lf the lRlG signal is

be ingdecodedproper lyby theopu, tnene|dwi | l : I9* " lR |GoK" , l f theDPUcannot decode the lRlG signal, the field'wilt show'lRlG Failure"' lf the DPU is a

\lt/

t

Time Master and if lRlG decoding has not been enabled (via a ggttino in ll]"TimeSync atom), the field will show "lRlG is not enabled"' Note that only the

active DPU of a opu pair decodes the lRlG signal. Thus, in a properly operating

DpU pair, the active dpU *itt indicate'lRlG Ok" and the inactive wil l indicate"lRlG Failure".

5.1.3 DPU TemPThis field indicates the temperature (in degrees Celsius) measured by a sensor

on the DPU.

5.1.4 DPU4F StatisticsFor maxDpus tne-ioirowing information appears in the center of the Details

display.The DPU name, |P address, current Time and Date, DPU serial number, DPU

hardware revision and service count (which corresponds to the size of the

downloaded configuration ).Current revision ievels for CP, lOM, CPLD, IOM FPGA, and the Shared Memory

FPGA. These fields correspond to various hardware and software components

within the DPU.current DPU run mode and state, Backup mode, other DPU state, Active

Pulses state, Other DPU Active Pulses state'

Alarm severity information for the specified oe.!J 9r DPU pair' The alarm fields

show total alarm counts for each opu tor severity levels 1 (the lowest severity)

through 5 (the highest severitY)'Fatal Error Reason indicates the reason that the cP has experienced a fatal

error. When the DPU is running normally, the field will contain "NA" (not

"ppii""Of"). lf a fata1 error oc",ir", descriptive text will appear instead' when

possible.soDlMM Status displays information about the soDlMM memory module

installed in the DPU. if a'standard memory module. is-installed, the field will show,,Standard,,. lf an error-chect<ing soDltvttvt'1e.g.,t81559) is installed and operating

properly, the field will show'Ok'. lf an error-Jhect<ing module is installed and if it

has detecteO a memory "r1"o|', the field will show a message such as.coRRyNONCOci Mem Erro/'. tt tnat happens, the Fatal Error Reason field will

"h"ng" from "NA" to "Memory Error Detected"'

The Time since Boot field shows how much time has elapsed since the DPU

was last started. Time since change shows the elapsed time since the DPU

underwent a major state change 1elg., if an Active DPU became lnactive)'

5.1.5 Function Block TimeThis field displays the percentage of available time (0-100%) that is being

consumedbyfunct ionb|ockswitnintheDPU.Thefunct ionblocksaredef inedinthe DPU's database and are downloaded to the DPU' Function Block Time is a

measure of DPU loading. lt gives an indication of how much logic may be run in

the DpU. Function gocfrir;e is displayed by means of a bar graph and a

numeric display. The color of the Uai i= gr"en for light loads and will turn yellow

and then red as the loading approaches 100%'

s