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Siemens SYSCON1 Manual

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

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Summary of Contents for Siemens SYSCON1

  • Page 1 Procedure to Install a CIM Door Retrofit in an Existing Airbath/Airless Maxum (SYSCON1/SYSCON+ with 5.10 or 5.20 Software) Difficulty Level: Medium Estimated time to execute: 2 Hours Revision History Issue Date Reason 8/18/12 Beta Draft 8/20/12 First Revision 8/28/12 Changes based on review.
  • Page 2 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...
  • Page 3 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.
  • Page 4 SYSCON1/+ External Ethernet (or internally mounted Ethernet device) Internal Ethernet CAC3 CIM Touch Screen Color Display Door Figure 3: Diagram of Ethernet and User Display Connections Final Configuration CIM Door Upgrade Page 4 IP-0021 SYSCON1/+...
  • Page 5 Siemens Field Service personnel be contracted to assist. • The Maxum analyzer must be equipped with SYSCON1 or SYSCON+. For analyzers equipped with SYSCON2, refer to procedure IP-0020. • A tool kit including both standard and metric wrenches, Hex wrenches, and screw drivers is required to perform this procedure.
  • Page 6 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).
  • Page 7 Not Used AT Bus Not Used PCI Slot 4 SYSCON 10Base2 Debug PCI Slot 3 CAN Bus PCI Slot 2 PCI Slot 1 I/O Terminal 10BaseT Blocks Figure 4 – SYSCON+ Board Connections CIM Door Upgrade Page 7 IP-0021 SYSCON1/+...
  • Page 8 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 Newer Board Assembly Figure 5 – SYSCON1 Cage Connections CIM Door Upgrade Page 8 IP-0021 SYSCON1/+...
  • Page 9 Figure 6 – CIM Board Connections CIM Door Upgrade Page 9 IP-0021 SYSCON1/+...
  • Page 10 Otherwise, the GCP installation may not complete properly. Continue the installation, answering any prompts from the screen. It is recommended that default options be selected. Repeat the installation for all computers that you wish to upgrade. CIM Door Upgrade Page 10 IP-0021 SYSCON1/+...
  • Page 11 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 SYSCON1/+...
  • Page 12 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 SYSCON1/+...
  • Page 13 “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 SYSCON1/+...
  • Page 14 CIM Door Upgrade Page 14 IP-0021 SYSCON1/+...
  • Page 15 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. Continue with the next section, Analyzer Door Replacement, immediately. CIM Door Upgrade Page 15 IP-0021 SYSCON1/+...
  • Page 16 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 SYSCON1/+...
  • Page 17 CIM Door Upgrade Page 17 IP-0021 SYSCON1/+...
  • Page 18 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 SYSCON1/+...
  • Page 19 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 SYSCON1/+...
  • Page 20 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 SYSCON1/+...
  • Page 21 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 SYSCON1/+...
  • Page 22 Remove the ground lugs from the door end. These will be reused on the new door. 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 SYSCON1/+...
  • Page 23 Step Procedure Remove door by lifting off hinges. Install new door onto hinges. CIM Door Upgrade Page 23 IP-0021 SYSCON1/+...
  • Page 24 Step Procedure 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 SYSCON1/+...
  • Page 25 Y-shaped cable will plug into the bypass cable. On the new CIM, verify that the switch settings are correct. CPLD Spare switches should all be Off (down). The I C Bus Pull-Up switches should all be On (to the left). CIM Door Upgrade Page 25 IP-0021 SYSCON1/+...
  • Page 26 Step Procedure 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 SYSCON1/+...
  • Page 27 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 SYSCON1/+...
  • Page 28 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 SYSCON1/+...
  • Page 29 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 Connect the ground clips from the door to the EC. CIM Door Upgrade Page 29 IP-0021 SYSCON1/+...
  • Page 30 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 SYSCON1/+...
  • Page 31 C connector of the power cable into any unused WDB I 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 SYSCON1/+...
  • Page 32 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 SYSCON1/+...
  • Page 33 At that point press the Home key on the screen and the boot menu should appear. Choose selection 5 (Configuration...) on the bootloader menu. Important: In SYSCON1/+ when no router (default gateway) is used, the IP Note: address for the router is set to 0.0.0.0. This is not valid for the CIM settings in the following step.
  • Page 34 Now that the IP settings for the CIM are correct, plug the green Ethernet cable back into the CIM. Allow the analyzer to reboot and allow it to come up. Using a hex wrench, replace the protective cover on the CIM board. CIM Door Upgrade Page 34 IP-0021 SYSCON1/+...
  • Page 35 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 SYSCON1/+...
  • Page 36 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. Put the analyzer back in Run and verify that all other operations are working as expected. CIM Door Upgrade Page 36 IP-0021 SYSCON1/+...

  • Page 37: Appendix 1: Troubleshooting Tips

    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 SYSCON1/+...

  • Page 38: Appendix 2: Fallback Procedure

    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. Using appropriate safety precautions, power down the analyzer.
  • Page 39 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. Apply power to the analyzer. The boot sequence should appear on the HMI.
  • Page 40 Verify that you can communicate to the analyzer via all external connections (e.g. GCP, Modbus). Verify that network broadcasts are received correctly. Put the analyzer back in Run and verify that all other operations are working as expected. CIM Door Upgrade Page 40 IP-0021 SYSCON1/+...
  • Page 41 Appendix 3: CIM Display Panel Operation CIM Display Panel Operation Overview 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.
  • Page 42 CIM Door Upgrade IP-0020 SYSCON2...

  • Page 43: Status Leds

    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).

  • Page 44: Screen Characteristics

    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: •...
  • Page 45 Screen Characteristics, Continued The status bar shows various data about the analyzer, including the Status Bar 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.

  • Page 46: Navigating The Menus

    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.
  • Page 47 Using the CIM Display, Continued The original Maintenance Panel for Maxum was equipped with a numeric Entry of Data 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.

  • Page 48: Accessing Help

    Using the CIM Display, Continued The online help function of the CIM Display represents a large leap Accessing Help 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.
  • Page 49 Using the CIM Display, Continued One useful feature of the online help function of the CIM display is the Alarm Help 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.

  • Page 50: Password Restrictions

    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.
  • Page 51 Password Restrictions, Continued Passwords can be modified from the User’s Passwords screen on the Obtaining/Changing a Configure menu. To change a password you must be logged on with Password “Super” level access. To change a password, select the table entry for the user and then tap (click) the “SELECT”...

  • Page 52: Appendix 4: Temperature Testing

    Appendix 4: Temperature Testing Note: If the customer does not have the equipment or experience to perform the following testing, then it can be arranged for Siemens Field Service to assist. Contact your Siemens Representative. In this procedure the user will determine the average internal temperature of the electronic compartment (EC), and compare it to the external ambient temperature.
  • Page 53 (without the CIM Door) below 60°C. Calculate: 60° – Observed Temperature Differential = Max Allowed Ambient. Example: For 15° Differential observed: 60° - 15° = 45° Ambient should not exceed 45°C CIM Door Upgrade IP-0021 SYSCON1/+...

This manual is also suitable for:

Syscon+