Harmony Controlway Problem
Harmony Controlway Problem
Harmony Controlway Problem
· Provide a description of the problem symptoms and a description of how this problem, dependent
upon your particular configuration, can affect system operation
· Explain how to identify if a specific Harmony system is susceptible to experiencing this problem
Problem Description:
The symptom of the problem is that some IMMFP12 or some PHCBRC100/200/300/400 modules may, in
isolated cases, experience a sudden but brief Controlway bus input value change. The bus input value, when
affected, may change to an incorrect value for ONE bus scan cycle. This condition applies to bus input points
(FC25 AI/B, and FC41 DI/B) and bus input lists (FC63 AIL/B, and FC64 DIL/B). The receipt of an
unexpected incorrect bus input value into a controller module for one scan cycle could negatively affect
system operation, possibly resulting in a related process trip or other system mis-operation, if the application
control logic within the receiving controller uses bus points for interlock purposes.
Module Identification:
A Harmony Process Control Unit (PCU) may be susceptible to experience this problem if one (or more)
modules communicating on a specific Controlway bus within that PCU is of a specific nomenclature type
AND if one or more of these module nomenclature types has a specific version of the Controlway design
installed. It is possible to determine if a given Harmony PCU is susceptible to experience this problem by
visual inspection of the module types and the Controlway version of each module type within that PCU. The
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3. INNPM12:
Inspect location U27 (middle center of the board assembly). If this location contains a daughterboard AND
the daughterboard is part number 6644789A1, this module can cause controller modules within the PCU
where the INNPM12 module is installed to experience the problem. The daughterboard part number will be
either silk-screened on the surface of the circuit board, or contain an adhesive label with the part number
printed on the surface of the label.
4. IMCPM02:
Inspect locations XU18 and XU19 (middle-right on the board assembly). If these locations contain a
daughterboard AND the daughterboard is part number 6644789A1, this module can cause controller modules
within the PCU where the IMCPM02 module is installed to experience the problem. The daughterboard part
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5. IMMFP12:
Inspect location U27 (middle center of the board assembly). If this location contains a daughterboard AND
the daughterboard is part number 6644789A1, this module can cause or experience the problem. The
daughterboard part number will be either silk-screened on the surface of the circuit board, or contain an
adhesive label with the part number printed on the surface of the label.
Instead of sending process critical signals across the Controlway bus, use physical I/O hardware to
pass this information between control applications.
2. Add Time delay / filter on all critical Controlway bus input signals.
Because the bus input value change is only momentary, the problem can be easily alleviated by
adding a time delay (or filter) to the bus input signal within the receiving module. The time delay (or
filter) needs to be configured such that the interlock logic does not respond to the momentary value
change. The required time delay must be greater than or equal to the module bus scan rate + one
controller module logic segment execution cycle time. For individual bus points (FC25 and FC41):
Bus scan cycle = S2 of FC82 + S13 of FC82. For bus input lists (FC63 and FC64): Bus scan cycle =
S2 of FC82 + S1 of FC63 or FC64. By default, the bus scan cycle will be ½ second (250msec +
250msec = 500msec).
With respect to Boolean bus input signals, the resolution is to add a FC35 TD-DIG block to the input
signal as shown in Figure 1. S2 of the timer = 1 (Timed Out), and S3 = calculated bus scan cycle (as
above).
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S1 0 S2 1
S2 0 S3 0.5
To Process Logic
AI/B
Real Bus Input Signal S1 (8)
2345 (25) S2 2346
S1 0 S3 10
S2 0 S4 10
1
1
For Real bus input signals the resolution requires engineering judgment. A straight forward approach
is to apply a rate limiter block (FC8) to the bus input signal (figure 1 above). Engineering judgment
is necessary to determine appropriate values for the increase and decrease rate limits (S3 and S4).
These specifications are in engineering units / second. Real process values cannot physically change
by more than 2-3% of span within one second. Therefore, values in the range of 4-10% of span
would be appropriate for S3 and S4 of the rate limiter block.
If the configuration in a back-up controller is viewed from Composer, the system response described above
can occur. To avoid this issue, do not view the configuration of a back-up controller module. Otherwise,
normal module operations (e.g. on-line configuration) function properly.
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If the Controlway communications (bus load) becomes saturated, if even as a temporary condition, the
system response described above can occur. To avoid this issue, it should be confirmed that no Controlway
bus saturation or overload conditions occur prior to installing the A2 version of Controlway. To operate
correctly, Controlway always needs to have available free time on the bus. It is also important to insure that
no momentary bus saturation “spiking” is occurring. So, even if the steady state bus load condition is quite
low, the system should be checked for any temporary or momentary bus load spiking conditions.
Sometimes, bus load spiking can occur due to the periodic time-alignment of system exception reports. This
condition can be avoided by staggering the max-times of exception reports (S8 of FC82) throughout the
system. For example, it is sufficient to stagger the max-times by a one second difference, so that PCUs have
unique max-times. This technique is also good general practice to provide communications load-leveling
within a system. In general, it is also good practice to eliminate any significant and unnecessary overhead in
the communications system. For example, significant change % of span (S9 of FC82) values should be
configured appropriately (e.g. 1% or 2%). Values under 1% likely will cause a constant flood of unnecessary
exception reports that burden the system with extra communications load.
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or * No upgrade needed *
N/A
PHCBRC20000000 With Daughter boards:
Since it is necessary to match the Daughter board upgrades with specific firmware as noted in the table, it
will be necessary to order Daughter boards and Firmware Upgrade Kits by module type. These module
specific kits will be available at time of order through Business On-Line (BOL) and other standard warranty
RMA channels.
PHCBRC30000000 and PHCBRC40000000 modules will either have a daughter board installed in location
XU15 (see Figure 2) or XU15 will be empty. If XU15 has the Controlway daughter board p/n 6644789A1, it
will need to be replace with the new daughter board (p/n 6644789A2).
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P13
XU15 U22
U26
U71
When XU15 does NOT contain a daughter board, inspect the label contained on either U26 or U71. If this
label contains the checksum E19B, this module must have the Controlway FPGA re-programmed. Order a
replacement module through BOL and/or other standard RMA channels.
PHCBRC10000000 and BRC20000000 modules that are installed and running with a Controlway ASIC
soldered onto the module, do not require any Controlway upgrade. PHCBRC10000000 or BRC20000000
modules that have Controlway on Daughter boards do not have any solution other than to upgrade these
modules to the current generation of PHCBRC30000000 and BRC40000000, respectively. A Step Up
program to exchange these modules will be announced by a separate product announcement.
Important Note:
Any PHCBRC30000000 and PHCBRC40000000 module in the field that does not currently have a
Daughter board installed is running Controlway functionality embedded in an FPGA. The Controlway
interface cannot be upgraded by installing a new daughter board. In fact, these modules will not function
properly if a Daughter board is installed. These modules must be returned so that the FPGA can be re-
programmed.
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As previously noted, please contact SupportLine with any questions about the technical aspects of this
bulletin. All commercial requests should be entered through Business-On-Line or your normal
warranty replacement channels. The following information will typically be required when placing a
warranty PO: original sales order, module types, number of each module type, serial numbers.
REVISION
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