Experion® PKS - TDC 3000® TAB PD 15

CUSTOMER PAGE Z99 (F)

RESOURCE MANUAL DATE 13 JUL 2016

PREVENTIVE MAINTENANCE PROCEDURES

Table of Contents

Sect. Description Pg.

1 Summary Information and GTAC Disclaimer .......................................... 2

2 LCN Maintenance ................................................................................... 3
3 Honeywell PC Maintenance .................................................................... 4
4 UCN Maintenance .................................................................................. 6
5 Check System Journals .......................................................................... 8
6 Check Cabinets and Consoles................................................................ 15
7 Check Temperature, Pressure, etc. ........................................................ 16
8 Check Atmospheric Corrosion Levels ..................................................... 17
9 Check AutoSave and Control States ...................................................... 18
10 Create and Use a Software Control Procedure....................................... 20
11 HM Clean-up and Backup Procedure ..................................................... 22
12 Fast Load Procedures and Identifying Application Failures .................... 26
13 Performance Monitoring.......................................................................... 27
A Appendix A - LCN Maintenance Checklist ............................................. 31
B Appendix B - PC Maintenance Checklist ............................................... 32
C Appendix C - UCN Maintenance Checklist ............................................ 33
D Appendix D – Cabinet and Console Checklist ....................................... 34
E Appendix E – System Audit Checklist .................................................... 35

Tables

Table Description Pg.

1 LCN Maintenance Checklist .................................................................... 31

2 LCN Maintenance Matrix ......................................................................... 31
3 PC Maintenance Checklist ...................................................................... 32
4 PC Maintenance Matrix ........................................................................... 32
5 UCN Maintenance Checklist ................................................................... 33
6 Cabinet and Console Checklist ............................................................... 34
7 System Audit Checklist ........................................................................... 35

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PREVENTIVE MAINTENANCE PROCEDURES, Continued

1. Summary Information and GTAC Disclaimer

Background Preventive Maintenance (PM) should be performed on a regular scheduled

basis. It depends on the site environment as the frequency a PM should be
performed. If there are contaminants at the site, the PM should be
performed more frequent. If the site is environmentally controlled, the audit
would not have to be performed as frequent. Each site should audit the
environment by checking for corrosion by using coupons or other devices to
periodically monitor the quality of the air. Other contaminants such as dust,
dirt, airborne particles, solids, equipment and floor cleaning chemicals, mice
nesting on boards, etc. will also need to be monitored and corrected or
eliminated.

Temperature, relative humidity and airflow also play a very important part in
control and equipment room environments to keep electronic equipment
failures down as much as possible. Age of power supplies, regulator boards
etc. need to also be monitored and replaced at recommended intervals
(usually 10 years). Logging of all of this information is imperative in keeping
a good record of when things get done and by who so others can find out if
items where checked or not properly, and if it needs to be modified to be
done more frequently than in the past.

NOTE: The following procedures are intended for consideration as a

guideline only. It includes relevant and critical information presented in a
general format. It is submitted and intended to act as a template for a PM
schedule that a customer can follow to fix communications problems,
suspect cables, node failures due to hardware problems, board and part
replacements due to corrosion or dirt and dust, etc.

When all of these procedures have been checked and done, and you still
encounter problems, please call your local Honeywell Global TAC (GTAC)
center during office hours or the North America (NA) GTAC center at 800-
822-7673, option #1. You can also open a Service Request (SR) online by
going to: https://www.honeywellprocess.com , Log in (or Register),
go to: Support > Request Help > Submit Support Request > fill out the SR
form and Submit it.

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2. LCN Maintenance

LCN Node To maintain and provide for the maximum equipment up-time and reliability,
Maintenance it is highly recommended that maintenance be performed on all LCN nodes.
Overview
The harshness of the environment the equipment is being housed in will
dictate the frequency of the maintenance. For maximum equipment
performance, the equipment should be housed in an environment that is:

 Climate controlled (temperature & humidity)

 Provides unrestricted air flow for equipment cooling fans
 Filtered to minimized outside airborne dust, dirt and other particles
 For extremely harsh conditions, the room should be under positive
pressure
 Limited access to equipment rooms to reduce the ingress of dust
and dirt from the process areas. If this cannot be done then the
frequency of maintenance needs to increase
 For control and equipment rooms with air contaminants, like sulfur
and chlorine, air purification may be necessary to bring them to a
G1 (ISA Standard), mild office environment (see Section 8 below).
HPM and other controller boards that are conformally coated can
withstand G3 harsh environments, but there’s a high probability
that corrosive attacks will occur here too. This harsh level should
prompt further evaluation and result in environmental controls or
specially designed and packaged equipment.

CAUTION
As with any activity, care should be taken not to effect production or expose
you to any hazards. All safety precautions should be followed. It is
recommended that prior to any work that the Operator be advised of the
tasks to be performed, an operational impact be raised and discussed with
the Operation Supervisor and a Job Safety Analysis be completed.

Frequency To maintain and provide for maximum equipment up-time and reliability, it is
recommended that all LCN equipment be checked and serviced on a
regular basis as per the maintenance matrix in Appendix A. In high traffic
and dirty areas this frequency needs to be increased to maintain a cleaner
environment.

Responsibility A site resource, who is familiar with the LCN equipment and standards,
should be assigned these maintenance tasks. They can also be carried out
by a Honeywell Field Service Specialist.

Maintenance Refer to Appendix A for a list of functions that should be carried out each
Activities maintenance cycle.

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3. Honeywell PC Maintenance

Honeywell PC To maintain and provide for the maximum equipment up-time and reliability
Maintenance it is highly recommended that maintenance be performed on all MMI (Man
Overview Machine Interface) Honeywell PC node types (client and servers), like
PCUS, TPS GUS/APP, Experion EST/ESC, ESVT/ESV, E-APP,
ACE-T/ACE, etc. The Experion nodes with a “T” at the end means that they
are connected to the TPS/TPN/LCN, the E-APP is considered an Experion
node that’s connected to the TPS/TPN/LCN. The PCUS is a US
replacement with a PC connected to the LCN, either with one or two
LCNP4e boards and MAUs, and it’s not considered an Experion station.

The harshness that the environment that the equipment is being housed in
will dictate the frequency of the maintenance. For maximum equipment
performance, the equipment should be housed in an environment that is:

 Climate controlled (temperature & humidity)

 Provides unrestricted air flow for equipment cooling fans
 Filtered to minimized outside airborne dust, dirt and other particles
 For extremely harsh conditions, the room should be under positive
pressure and may need air purification filters
 Limited access to equipment rooms to reduce the ingress of dust
and dirt from the process areas. If this cannot be done then the
frequency of maintenance needs to increase
 For control and equipment rooms with air contaminants, like sulfur
and chlorine, air purification may be necessary to bring them to a
G1 (ISA Standard), mild office environment (more info in Section 8
below). PCs should not go into any harsher environments than G1
since their components, like boards, drives, power supplies, cable
connectors, etc., may fail sooner than expected for the duration of
their standard manufacturer warranty (3 years).

CAUTION
As with any activity, care should be taken not to effect production or expose
you to any hazards. All safety precautions should be followed. It is
recommended that prior to any work that the Operator be advised of the
tasks to be performed, an operational impact be raised and discussed with
the Operation Supervisor and a Job Safety Analysis be completed.

Frequency To maintain and provide for maximum equipment up-time and reliability, it is
recommended that all MMI equipment be checked and serviced on a regular
basis as per the PC Maintenance Checklist and the PC Maintenance Matrix
in Appendix B. In high traffic and dirty areas this frequency needs to be
increased to maintain a cleaner environment.

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Responsibility A site resource, which is familiar with the MMI equipment and standards,
should be assigned these maintenance tasks. They can also be carried out
by a Honeywell Field Service Specialist.

Refer to Appendix B for a list of functions that should be carried out each
Maintenance
maintenance cycle.
Activities

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4. UCN Maintenance

UCN Node To maintain and provide for the maximum equipment up-time and reliability
Maintenance it is highly recommended that maintenance be performed on all UCN
Overview nodes.

The harshness of the environment the equipment is being housed in will

dictate the frequency of the maintenance. For maximum equipment
performance, the equipment should be housed in an environment that is:

 Climate controlled (temperature & humidity)

 Provides unrestricted air flow for equipment cooling fans
 Filtered to minimized outside airborne dust, dirt and other particles
 For extremely harsh conditions, the room should be under positive
pressure
 Limited access to equipment rooms to reduce the ingress of dust
and dirt from the process areas. If this cannot be done then the
frequency of maintenance needs to increase.
 For control and equipment rooms with air contaminants, like sulfur
and chlorine, air purification may be necessary to bring them to a
G1 (ISA Standard), mild office environment (more info in Section 8
below). HPM and other controller boards that are conformally
coated can withstand G3 harsh environments, but there’s a high
probability that corrosive attacks will occur here too. This harsh
level should prompt further evaluation and result in environmental
controls or specially designed and packaged equipment.

CAUTION
As with any activity, care should be taken not to effect production or expose
you to any hazards. All safety precautions should be followed. It is
recommended that prior to any work the Operator be advised of the tasks to
be performed, an operational impact be raised and discussed with the
Operation Supervisor and a Job Safety Analysis be completed.

Frequency To maintain and provide for maximum equipment up-time and reliability, it is
recommended that all UCN equipment be checked and serviced on a
regular basis as per the Maintenance Matrix in Appendix C. In high traffic
and dirty areas this frequency needs to be increased to maintain a cleaner
environment.

Responsibility A site resource, which is familiar with the UCN equipment and standards,
should be assigned these maintenance tasks. They can also be carried out
by a Honeywell Field Service Specialist.

HPM Preventive Also refer to the HPM Service manual, HP13-610, for a list of functions that
Maintenance should be carried out each maintenance cycle.

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HPM Preventive All maintenance procedures are in the HPM Service manual. For the most
Maintenance part, the components that require attention are the power systems, battery
(continued) replacement, etc. Also should wire up the alarm contacts on the power
systems to monitor at the DCS (stations). Everything else is just
housekeeping; clean the filers regularly, keep the rack room free of dust,
dirt and contaminants. There are no periodic calibrations required for the
xPM.

The HPM Service manual also goes into maintenance displays that shows
you how to look up error, failures, and how to do periodic redundancy tests,
periodic maintenance parts list (batteries and fuses), etc.

Hot Spares Check hot spare and regular spare holdings to make sure that critical parts
(IOPs, FTAs, etc.) are available and in working condition or new.

Frequency Annually.

Procedure Check hot spare items to make sure that they are kept in a secure and
clean environment. Verify any additional parts that should be added or
replaced as necessary.

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5. Check System Journals

Check System The System journals should be checked to make sure that there are no
Journals unexplained status changes or errors that would need to be looked into
further.

Frequency Weekly.

Procedure Using For the System Status Journal (SSJ), System Error Journal (SEJ) or
System Menu System Maintenance Journal (SMJ):

On an Engineering station in a US or Native Window in a GUS/EST, carry

out the following steps:

1. Press Ctrl + Help simultaneously on the Engineering Keyboard at a US or

CTRL + NUM LOCK on a GUS/EST to display the “Engineering Main
Menu” (or in Native Window, can pull down Engineering > Menu)
2. Select SYSTEM MENU (or press the keyboard button for System Menu)
3. Select EVENT HISTORY MENU
4. Select SYSTEM STATUS (and/or the SYSTEM ERROR, SYSTEM
MAINT - Maintenance)
5. Select ALL NODES
6. Select START DATE and type in a date one week ago
7. Select START TIME and type in 00 00 (midnight in military time)
8. Leave the END DATE and END TIME to the current date and time
9. Select DISPLAY to display journal entries
10. PAGE FWD/DOWN as necessary to view all entries.

Use the ROLL RIGHT and ROLL LEFT targets at the bottom to examine
the data in the entire line and determine if any of the messages require
attention. If any message(s) do require attention, and you need help
interpreting the information, repeat the above process using appropriate
START and STOP dates and select PRINT at step 7 above (or do screen
prints of both sides of the pages). Preferably, if a Virtual Printer is set up
(#11-29, see attachment from the Engineering Reference Manual,
Section 32), can print to a file and use File Transfer to copy it to a PC, then
copy it to a USB jump drive and attach it to the Service Request (SR) or
send it in an e-mail to GTAC for further analysis after opening a SR.

Note that you can open a SR online by going to:

https://www.honeywellprocess.com , Log in (or Register), go to:
Support > Request Help > Submit Support Request > fill out the form and
Submit it. Attach the journal information from above to the SR.

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Procedure Using Another method of collecting System Journals is by using the Documentation
Documentation Tool (DOCTOOL or Doc. Tool):
Tool
1. ENGINEERING MAIN MENU
2. Select DOCUMENTATION TOOL
3. Select QUERY
4. Select Build
5. Select Jrnl
6. Enter the Start Date-Time the LCN had this issue
Using DOCTOOL the format is as follows:

Examples Format Contents

------------- ---------- ------------
3/17/16 Numeric “month”/’day”/”year”
17/mar/16 European “day”/”alpha month”/”year”
1677 Julian “year” ”day”

If you place your cursor in the “Start Date-Time?” field, and press the
HELP (or if you are using the PC keyboard, press NUM LOCK key) you
will see how the date and time must be entered
7. Enter the “End Date-Time?” (NOTE: Leaving it blank makes the end
date/time default to the current date and time - now)
8. Select at right JRNL Sort
9. Select System Maint. Messages, System Status Changes and System
Error Messages
10. Can Save this query for future use by entering a title in the “Descriptor”,
and selecting “Save”. If modifying a previous query, will also need to
select “Overwrite”
11. Press ENTER
12. Should see at the bottom: “Query in progress”
13. Wait for “Operation complete” to be displayed at the bottom of the page,
should also see the first screen with journal info in it divided into columns
14. Select OUTPUT
15. Select “To a File”
16. Enter a valid pathname for this data to be saved such as:
Net>DIR>journals.XX, where DIR = a User Directory in the HM
17. Select Output in CSV
18. Press ENTER
19. At the bottom you should see: “Request in progress”
20. Wait for “Operation complete”
21. Send this file in to GTAC for analysis once a SR is opened. Can use File
Transfer to copy it to a PC (or print to a Virtual Printer file), then copy it to
a USB jump drive and attach it to the SR’s e-mail response back to the
GTAC Engineer (use “Reply All”), or use our website above to attach it to
a new or existing SR.

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SMCC In the event that there are maintenance messages of concern, please refer to
Maintenance the manual Maintenance Test Operations, SW11-502, to verify if there’s a
Errors Summary problem. Also below is info on how to see these maintenance messages.

NOTE: To access the SMCC/Maintenance section you will need to have

Engineering key access. The information contained in this area is volatile and
will be deleted if the node is shutdown and reloaded (but will be maintained
in the System Error Journal). On an Engineering station in a US or Native
Window in a GUS/EST, carry out the following steps:

1. Press Ctrl + Help simultaneously on the Engineering Keyboard at a US or

CTRL + NUM LOCK on a GUS/EST to display the “Engineering Main
Menu” (or in Native Window, can pull down Engineering > Menu)
2. Select SMCC/MAINTENACE
3. Select MODULE ERROR
4. Select MODULE ERRORS SUMMARY
5. Type a valid node number that’s in your system in the “Module Number”
and press ENTER on the station’s keyboard
6. Review the data
7. On the Engineering keyboard press PAGE FWD/DOWN
8. Review the data
9. Keep paging down until you have seen and read all pages for this node
10. Repeat Steps 5-9 for all nodes
11. To see more details on these errors, which the node can retain the last
32 errors since it was last reloaded, do Steps 1-3 above, then…
12. Select DETAILED MODULE ERRORS
13. Then do Steps 5-10 above.

NOTE: When a node fails, the first error that shows would be the latest. Do
a screen print of it and attach or send it in for the SR, along with the System
Status and System Error Journals around the time of the failure, a little
before and after. Also, if present, please send in this file:
Net>&ASY>ERRBK.XX. The GTAC Engineer may also need a memory
dump to removable media (zip or emulated drive). This would need to be
done at the time the node fails. The attached procedures should be used.
Please attached it to the website SR you made or send it in when asked to
do so.

GTAC does have the most common error codes and a memory dump may
not be necessary. If you see in the in the node that failed that the latest
error in the memory, using DETAILED MODULE ERRORS, has a TASK
NAME of all asterisks: *********, then this means there’s a hardware
problem in the node and would need to start cleaning and/or changing
boards in it, one at a time, and there’s no need to send in a memory dump,
since there’s no software troubleshooting to be done. Usually the node fails
showing in the node’s LEDs -190 (Illogical Condition), but this is a catch-all
error code for most hardware and software failures, and doesn’t help much
by itself.

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Clearing the 1. From the ENGINEEERING MAIN MENU, select SMCC/MAINTENANCE

Active target
Maintenance 2. Select ACTIVE MAINT JOURNAL
Journal
3. Select DISPLAY ACTIVE MAINTENANCE RECOMMENDATIONS AND
ENTER CORRECTIVE ACTION target
4. ALL will be displayed in the ENTER Module Number. Press the ENTER
button. See Figure 1
5. Print the screen of the Active Maintenance Journal display. Some
examples that should be investigate and resolved:
 Replace Marginal LCNI Cable-A > Cable A is suspect
 Replace Failed Module Fan > bad fan or wrong revision of LCN I/O
 Investigate Suspect K4LCN-8MW Ctrl > bad board, perform
preventive maintenance (clean or replace the board)
 Investigate Suspect SPC Ctrl > bad SPC or SBHM board or HM
drive
 Investigate Suspect Cursor Device > dirty or bad touchscreen
 Test Suspect LCN Subsystem > Peripheral error, printer, drive, kb.
6. Write CLEAR or OK or whatever you like by the ENTER CA Text port (CA
is for Corrective Action)
7. Select any maintenance recommendation line to clear it and press the
Enter button. That particular line goes away. Do this for all entries, one at
a time, in all pages of the Active Maintenance Journal Data for all nodes.

Figure 1
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Print Error 8. Press the PAGE UP/BACK keys two times.

Aggregates
9. Select the target at the bottom of the screen PRINT ALL ERROR
AGGREGATES

10. If any nodes have had errors on their boards since the History Module
was last reinitialized (or the files with the information deleted – see
below), it will print one node per page

11. Review the printed report. To the right there will be either an error count
that would say INCREASING (bad) or DECREASING (good)

12. If the report has DECREASING it means the software was able to correct
the hardware problem (EDAC – Error Detection And Correction)

13. If the report is INCREASING, this means the software is unable to

resolve the hardware problem and that board needs immediate attention

14. If the board is under warranty, replace the board with a new one

15. If the board is out of warranty, shutdown the node 2 times (places it into
the FAIL state), power the node down (unless this node contains a LCNE
fiber optic board) and remove and clean each board with non-static dry
air spray to clean it. Electrostatic Discharge (ESD) protection must be
used when handling boards. Wait 24 hours and print the ERROR
AGGREGATES report again to determine if the board's errors are
DECREASING. If still INCREASING is reported, the board should be
moved to another node, which has the same board type. For K2/K4, you
will have to change the LCN Address on the board. Wait 24 hours and
print the Error Aggregates again. If the board is still reporting an
INCREASING error count, replace it with a new one.

NOTE: If you move a board or replace it with a different board type, the
OPT (On Process Test) will not check the new board. If you must replace
the board with another board type, like a K2LCN with a K4LCN board,
follow the "Procedure to Clear the Error Aggregates from a Running
System" directly below. Also, in a 10-slot or 5-slot LCN chassis, if the first
board is more than two slots away from the K2/K4 processor in slot 1, the
OPT test won’t occur, so you won’t know whether the other board(s) in
that node are good or not. Also, the paddle boards in the other side of
any LCN chassis, including the Dual Node Card File (DNCF) are never
tested nor printed out in the ERROR AGGREGATES report.

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Procedure to This procedure is to be performed when board processor types have been
Clear the Error changed in node(s), for example from K2LCN to K4LCN, or if you want to
Aggregates get another starting point from previous error aggregates. If this is not
performed, the SYSTEM History Module must be initialized.

1. From the command processor type LSV NET to determine which HM has
the !ESY directory

2. Copy the files from directory !ESY to formatted removable media, like an
emulated drive:
CR $Fn>!ESY
CP NET>!ESY>*.* $Fn>!ESY>=
where: n = drive number

3. Load the HM into the Offline personality.

NOTE: If the HM Volume Configuration is setup for HMI (Initialization, Init.)
personality, which is the default, you can load the HM from itself using
DEFAULT SOURCE for everything. The HM status will go to HMOF OK
status

4. In the Command Processor type:

PT PN:nn>!ESY>CA*.CM
where nn = the HMs LCN node number

5. Type:
DL PN:nn>!ESY>*.* (the error FILE PROTECT OR ACCESS VIOLATION
will be displayed due to CA*.CM being protected, can disregard it)

6. Type:
UNPT PN:nn>!ESY>*.*

7. Reboot the HM (this will recreate the deleted files):

 Select the LOAD/DUMP target
 Select MANUAL LOAD target
 Select OPERATOR PROGRAM target
 Select DEFAULT SOURCE and the EXECUTE COMMAND targets
 Select DEFAULT SOURCE and the EXECUTE COMMAND targets
 Press the ENTER key. The HM will reload. Wait for the HM to go to
 Select HIST COLLECT
 Select ENABLE COLLECT to Enable History Collection
 If the HM has disk redundancy, type in the Command Processor:
SYN PN:nn
where nn = the HMs LCN node number
 Press ENTER. The synchronization of the redundant drives can take
several hours and runs in a background mode which won’t interrupt
other programs that are running in the HM, like history and checkpoint
collections

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Procedure to 8. Perform an “Initiate On-Process Analysis Cycle” and check the Error
Clear the Error Aggregates printout (one node per page):
Aggregates,  From the Engineering Personality Main Menu
continued  Select SMCC/Maintenance
 Select Active Maint Journal
 Select Initiate On-Process Analysis Cycle
 The bottom of the display will show “On Process Analysis (OPA) In
Progress”
 When finished, at the bottom of the display will show “On-Process
Analysis (OPA) Complete”
 Select PRINT ALL ERROR AGGREGATES
 Wait for the printout to complete
 If there are no errors, it is normal to get the message: "Non-
Existent Aggregate Record". If any node is printed in the journal
with INCREASING errors (on the right side of the page), corrective
action is required (see next 3 bullets). DECREASING errors are
OK, can be ignored.
 If the board is under warranty, replace the board. If the board is
out of warranty, clean the board(s) and re-insert. Wait until the
next day and do another PRINT ALL ERROR AGGREGATES
report again. If the problem persists, move the board to another
node which has the same board type(s) (check the LCN Address
on it for K2/K4 boards).
 Let the node run for another 24 hours and do another PRINT ALL
ERROR AGGREGATES report again.
 If the report shows the new node with the board that you moved
into it still showing INCREASING errors on the bad board, replace
the board.

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6. Check Cabinets and Consoles

Cabinets and For each cabinet and console, check and document the cables,
Consoles terminations, power, grounding, and filter conditions in accordance with
Table 1 in Appendix D.

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7. Check Temperature, Pressure, etc.

Temperature, Measure and document temperature, pressure, humidity, light, sound and
Pressure, Extremely Low Frequency (ELF), which is a designation for
Humidity, Light, ElectroMagnetic Field (EMF) radio wave levels, in each room with
Sound, and ELF Honeywell Equipment.
Levels Take at least two readings of room temperature at different locations, and
average them for the external temperature reading. Allow ten minutes
stabilization time per reading.
Take at least two readings of room humidity at different locations, and
average them for the external humidity reading. Allow ten minutes
stabilization time per reading.
Measure the absolute pressure inside and absolute ambient atmospheric
pressure outside, and note the difference.
Measure the Noise, Light and ELF levels outside each cabinet and console,
holding the meter at head height (sitting head height if in front of a console).
Keep all cabinet and console doors shut while doing this. Follow the
specific instructions for each meter type.
For each console with a screen, judge the quality of the screen display, in
terms of brightness and contrast with ambient light levels and reflected
glare.
All radios, cell phones, portable phones, and any other communication
devices should be kept 3 meters (10 ft.) away from all Honeywell
equipment, except for xPM (PM, APM, HPM) equipment, which then they
can be 1 meter (3.3 ft.) away.
This information can be found in the Binder 3020-1, TPS System Site
Planning, SW02-550, 7/96, Section 12.5, page 145, last paragraph (which
mentions 5-watt radios, but applies to all communication devices):
"Because it is difficult for a hand-held unit to have a radiation efficiency of
even 50%, keeping a 5-watt unit 1 m (3.3 ft.) from a PM, APM, or HPM
works well. All other TPN/LCN, TotalPlant Solution (TPS) and Experion
System products require a separation of 3 m (10 ft.)."

Ventilation and Check and document the ventilation and filtration in each room with
Filtration Honeywell equipment. Check the System Site Planning Manual, Sections 7
and 8.

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8. Atmospheric Corrosion Levels

\

Atmospheric Place silver and copper test coupons to monitor atmospheric corrosion
Corrosion levels. Follow specific instructions on how to handle these coupons, which
should hang near the equipment affected for one month (several may be
needed). Return the coupons for analysis. Contact your local Field Service
Specialist or Manager or GTAC on how to obtain corrosion test coupons.
Corrosion of contacts and components on circuit boards accounts for ~30%
to 40% of all equipment failures. This corrosion, sometimes called
eCorrosion, is caused by an unmanaged environment consisting of
combinations of uncontrolled temperature and humidity, along with harmful
corrosive gases inside the electronic equipment rooms.

A growing number of electronic reliability problems develop when DCS

(Digital Control System) equipment is exposed to environmental conditions
exceeding Honeywell HPS’ specifications. Honeywell’s Global Technical
Assistance Centers (GTAC) are receiving an increasing number of
complaints on early life failures due to eCorrosion, resulting in unplanned
warranty, and other maintenance and replacement related costs. These
unwarranted complaints can develop into customer’s misconception of poor
DCS reliability.

The environment surrounding Honeywell’s control systems and electronic

equipment must be properly managed for successful system operation and
reliability. The customer must manage several environmental species of
airborne contamination, such as:

 liquids, including micro levels of condensation, sea salt mist

 solids, including grit, sand, and dust
 gases, including Inorganic chlorine, active sulfur (hydrogen sulfide),
sulfur oxides, SO2 and SO3, and Nitrogen oxides, NOx, and
hydrogen fluoride, ammonia, ozone, and other strong oxidants

Being aware, knowing the requirements, and how to assess and monitor
corrosion rates will help. A few “less than obvious” eCorrosion failure modes
are also presented in the attached Whitepaper on Control System
Environment.

Earth Testing Refer to the High-Performance Process Manager Checkout Manual HP20-
Procedures 510, FSC Service Manual FS99-504 and TPS System Site Planning SW02-
550

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PREVENTIVE MAINTENANCE PROCEDURES, Continued

9. AutoSave and Control States

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Check Cable, Check to make sure how the settings are for AutoSave and Control States
AutoSave and and check cables.
Control States

Frequency Daily.

Procedures For each Application Module (AM), carry out the following steps:
1. Press the SYST STATS button
2. Select an Application Module (AM – primary if redundant)
3. Select NODE STATUS
4. Select the first Application Module
5. Select AUTO SAVE and Check it is appropriately set for the Current
State (Enable Save/Disable Save)
6. Repeat for all other Application Modules on this system (primaries for
redundant sets).

For each Computing Module (CG), carry out the following steps:
1. Press the SYST STATS button
2. Select a Computing Module
3. Select NODE STATUS
4. Select the first Computing Module
5. Select AUTO SAVE and check it is appropriately set for the Current State
(Enable Save/Disable Save)
6. Repeat for all other Computing Modules.

For the Network Interface Module(NIM), carry out the following steps:
1. Press the SYST STATS button
2. Select the first primary NIM
3. Select NODE STATUS
4. Select AUTO SAVE and check that it is appropriately set for the Current
State (Enable Save/Disable Save)
5. Repeat for all other primary NIMs on this system
6. Press Ctrl and PAGE FWD/DOWN to go to the next node type.

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Check Cable, For each UCN, carry out the following steps:
AutoSave and 1. Press the SYST STATS button
Control States 2. Select the first primary NIM with the first UCN Network number
Procedures, 3. Select NTWK/HWY STATUS
Continued 4. Select AUTO CHECKPT and check that each UCN, NIM (top right), and
Devices (like HPMs, SMs, etc.) have the appropriate settings for Auto
Checkpoint. The NIM Auto Save needs to be done per above
5. Select CONTROL STATES and check that each UCN, NIM and Devices
(HPMs, etc.) have the appropriate settings for their Control State, which
would need to be FULL instead of BASIC when controlling from AMs
6. Select UCN CABLE STATUS
7. Ensure “Cable Swapping” is enabled for all nodes and that the cable is
swapping between cables A&B
8. Repeat for all other UCN Networks.

For each HG and PLCG/EPLCG (HG with emulated Hiway boxes), carry out
the following steps:
1. Press the SYST STATS button
2. Select the primary HG (that may be a PLCG/EPLCG) with the first HWY
# and check that the CTL STATUS (FULL/BASIC) and HG CKPT STS
(Enable/Disable) are appropriately set
3. Check to see if AUTO CBL SWP and PER (Periodic) CBL SWP are
appropriately set (Enable/Disable)
4. Select BOX STATUS
5. Type in the first box number
6. Check that the “Control Status” (FULL/BASIC) and “Checkpoint Status”
(Enable/Disable) are appropriately set
7. Press Ctrl and PAGE FWD/DOWN to go to the next box
8. Repeat for each Hiway Network.

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10. Create and Use a Software Control Procedure

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Create and Use This should be kept in the Site Log. Create a procedure which can be used
a Software during commissioning, and during ongoing operation of the system to
Control maintain and log changes to the control system.
Procedure
If any changes require modification to documentation/drawings, then these
should be red-lined and sent to the appropriate authority, and/or directly
modified if available electronically. A topology of the system (map showing
node info like location, cabling, LCNEs, cable distances, clock Master/Slave,
UCN nodes, Hiway boxes, C300 cabinets, switches, etc.) should be kept up
to date.

Panel Log Most sites require that a site/panel log be filled in, detailing all work carried
out. During the life of the system it can provide invaluable information, some
faults can be intermittent, occurring only once every year or so.
Each entry in the log may be preceded by a header line, with the following
format:

Date---Initials---Requester---Description---Status---RefNo

As a minimum, the tagname whose parameter was changed along with the
Point Changes “before” and “after” values should be documented in the panel log.

System As a minimum, all other changes that are made should be fully documented
Miscellaneous in the panel log, along with descriptions of the “before” and “after” values.
Changes
1. Always make Online NCF changes (never Offline, which would require
NCF Changes
all nodes to be shutdown at the same time and reloaded) after setting up
a backup pathname in the Engineering Main Menu > Support Utilities >
Modify Volume Paths > in the “NCF Backup Path” put $Fn>&ASY, where
n = drive number in this Station with a mounted zip disk or emulated
drive, which needs to be formatted in the Command Processor to have
an &ASY in it (volume or directory name). The main pathname is set to
NET>&ASY if the change is not for this HM (otherwise $Fy>&ASY, where
y = different drive # than “n” for the Backup pathname)
2. Refer to the Engineering Reference Manual, SW09-605, and the Network
Data Entry Manual, SW11-605, before making changes
3. On a “dry run” take note of what advice the checker Ctrl + F1
(Engineering Keyboard) or Ctrl + 1 (PC keyboard) provides
4. If the change is extensive and/or complex on nodes that have to be
reloaded, seek advice from someone who has made this change before
or would know if the nodes can be reloaded (or call the FSS or GTAC)
5. Always use Ctrl + F5 (Engineering Keyboard) or Ctrl + 5 (PC keyboard)
and press Enter to abort and delete the NCF.WF (Work File) before
making any changes or if just viewing the NCF

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NCF Changes 6. Ensure that any HM modifications required are also implemented in
Continued Volume Configuration, like when adding a node that requires a
checkpoint or adding history. You’ll need to run a HM Backup, initialize it
and Restore all files, see the Network Data Entry manual, Table 7-36, for
other steps
7. Always leave “White/No Impact” nodes non-reloaded, can be viewed
from the System Menu > NCF Status display. All cyan/blue, yellow or red
nodes need to be reloaded ASAP with the new NCF timestamp.
Eventually should try to get the NCF in synch and in green for all nodes,
which when you have cable problems it would help in troubleshooting.

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11. HM Clean-up and Backup Procedure

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Clean Up History Periodically the History Module (HM) should be looked at to see if there are
Module unwanted files in it.

Frequency Quarterly.

Procedure Make an EC File. There should be a directory on the HM for ECs. There
should be a directory on the HM that is used to store temporary files. The
System name for this directory is SCR. This EC will list all files designated to
be deleted in SCR for review, before they are completely removed from the
System. This EC will locate all files with the extensions of BU, LE, EF, DY,
UL, and SL and list them for deletion.

HM Backup Full History Module (HM) backup to be taken. Create HM Backups to ensure
the system has a way to recover in case of hard drive(s) issues problems.

Frequency Monthly, depending on changes being made to the database, schematics,

and other files. If any of these type of changes going on a weekly HM
backup is more appropriate.

Procedure A System History Module (the one with the &ASY and personality files such
as &UNP &UCN, etc.) backup is to be performed at the schedule indicated
to removable media (zip disks or emulated drive). All HM backups will be
store in an appropriate location or multiple PCs (in case of PC drive failure)
and reviewed to confirm that they are a viable backup.

Sample Before running a HM Backup, should pre-format the zip/emulated drive

Procedure before running the Backup with a larger value for –MF (Max Files). Please
see the instructions below. Notice the pre-format for –MF in Step 6 below to
10,000 files (should stay under 32,000 files, can always do a list of all the
files in the HM (LS PN:nn>*>*.* where nn = HM node #) and round it up to
the next 1,000 file, so for 7,543 files, make –MF = 8000). Note that with the
format given below, you may actually fit the backup to less zip disks or
emulated drives so you wouldn’t need to dismount/mount new ones to
continue the Backup or the Restore.

Example:
CR $Fn>BKUP> -F –MF 10000 –BS 1700 -X

Also, if you have large files in the HM with lots of records (more than
10,000), like files for Virtual Printers that keep appending logs to the same
file over and over again, you should delete them first since the File Manager
will get an error after 15 mins. of trying to copy the file and may abort the
Backup. May need to run the Backup over again after each delete of a large
file.

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HM Backup To backup the entire HM volumes, directories and files, except for history
Sample (for points as well as for all the journals), you can follow these instructions.
Procedure 1. In the Command Processor, run and save a screenshot of a LSV>NET
Continued to list all volumes
2. Saving history group points into an EB file. If the History Group Point
definitions do not already exist in the EB files, perform the steps below to
build and save the History Group Point definitions to EBs.
A. Using the Text Editor and following the syntax example,
BUILD History Group Point definitions list.
EXAMPLE SYNTAX:
$CHui(gn)
where ui = Unit Index number (from UNIT NAMES
under the Engineering Main Menu,
Unit Names, under the column labeled ‘‘NO’’)
gn = History Group number in unit
EXAMPLE:
$CH01(01) $CH01(02) $CH01(03) $CH01(04)
$CH01(05)
$CH02(01) $CH02(02) $CH02(03) $CH02(04)
NOTE: Place four spaces between each definition
B. PERFORM DEB PRINT SYSTEM ENTITIES using the
saved selection list. This saved file should have an .EL extension.
OUTPUT to a file in the Net with .EB extension.

3. Insert a zip disk into a US’s zip drive (on a GUS/EST mount an emulated
.lcn file with size of 500MB and Allocation = Dynamic).
4. In the Console Status display, find out the drive number for the zip drive
that has this zip disk.
5. Go to the Engineering Main Menu > Command Processor.
6. Type in the line at the bottom where the cursor is at:
DO Net>DIR>BACKUP.XX and press Enter, where: DO = Data Out, DIR
= User directory name in your HM. This will output to a file the info that
the Backup command puts on the screen (and rolls off it) in case you get
errors during the copy command, so you can view it later on in the Text
Editor.
7. Type in PD ON and press Enter, where PD = Physical Device. This will
put into the above file your instructions that you enter in the Command
Processor.
8. Type in CR $Fn>BKUP> -F –MF 10000 –BS 1700 –X and press Enter,
where: CR = Create/Format, n = drive #, F = Format, MF = Maximum
Files, BS = Block Size for transfer, X = use eXtended directories to 2047
max. (instead of just 64).
9. Wait for Operation Complete message, takes about a minute or two.
10. Do 4&5 for other zip disks in a US (at least 5). Don’t have to repeat on a
GUS/EST.
11. Type in BACKUP PN:nn $Fn and press Enter, where nn = node number
of the HM, n = drive #

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Sample 11. The Backup command puts up info on the screen, which you can
Procedure read, and asks you if you want to format the media in $Fn, type NO
Continued and Enter it.
12. Wait hours for the copy to complete. If backing up to zip disks, you’ll
be prompted when to put in the next one (when it gets full). Label
each zip disk (1, 2, 3…).
13. Wait some more…repeat 11&12 if on a US.
14. The Backup command will tell you when it’s complete (finished). You
can view the BACKUP.XX file in the Text Editor to see how many
errors there where, and if they are critical or not. Expect at least 1
error since you had this file open and it couldn’t back it up. To view
the file is: ED NET>DIR>BACKUP.XX and press Enter. Page
forward to see the entire file for errors. Call TAC if you don’t know
what the errors may mean.
15. On a US, take out and label the last zip disk. On a GUS/EST,
dismount the emulated drive.
16. You can either type in DO and press Enter to terminate the Data Out
command, type in End and press Enter to get out of the Command
Processor, or hit CTRL+ Help to go to the Engineering Main Menu.
17. Done, store the zip disks in a safe place. The HM Backup should be
done periodically in case you lose an HM drive, get files corrupted,
overwrite files, change NCF, change or add new files, etc. You
should also keep older version of backups around in case you have a
need to retrieve a file from them.
18. There are other procedures for initializing new HM drives and running
the RESTORE $Fn PN:nn, which copies the files back to the HM.

SBHM Alternate History Module backups will be stored on the site storage node(s) as
Procedure indicated in the site’s backup procedures document. Should have several
backups from different dates available in case of file corruption. Backups
can be copied to USB jump drives and kept locked in case of future needs.

With Single Board History Modules (SBHMs) that have small drives on the
board, if you have drive redundancy and have spare drives, you can actually
put a redundant drive Offline and insert another one and synch it. That way
you can store the redundant drive under key in a cabinet as a backup too.
To do this while the SBHM is running in OK with redundant drives:

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SBHM Alternate 1. In the Command Processor run: OFFLINE PN:xx 4 and

Procedure OFFLINE PN:xx 2, where xx = SBHM node number, the SBHM will go to
Continued Warning
2. Power off the left-hand drive with the toggle switch by it
3. Gently pull out the left-hand drive with the board under it
4. Insert all the way in a new formatted drive in the left-hand drive
position
5. Power on the the toggle switch by the left-hand drive
6. Wait 2 minutes until you see in the SBHM’s Status Detail display
going from Not Present to Offline. Will need to refresh the display,
doesn’t update automatically
7. In the Command Processor run a synch: SYN PN:xx, where xx =
SBHM node number. The synch usually will take a 1 to 8 hours to
finish in background mode, then the SBHM will go to OK
8. Label the drive you took out with today’s date and store it someplace
safe.

Note: Shouldn’t synch an old drive to the current running drive, or a drive
from another system SBHM in this system SBHM. The way the SYNCH
command works is by copying volumes, usually from the main drive the
SBHM autobooted from (usually drives 5 and 3 on the right-hand side if
powered on) to the redundant drive (4 and 2 on the left-hand side). But if it
detects a volume corruption on the main drive, it will synch in the opposite
direction, possibly replacing newer files with older ones. That’s why you
either need to use a new formatted drive or format the drive with HVTS
SCMD Test 19 beforehand (which can take several hours to do, preferably in
an offline system). GTAC advises to use new formatted drives instead of
using HVTS to format them, since will also need to take a station offline and
learn how to correctly setup the parameters for it, besides taking hours to
format it, not an easy task.

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12. Fast Load Procedures

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Fast Load Disk In case of power failures or when the system HM is not available to load
nodes, a Fast Load should be made beforehand and kept at each Console
so that critical nodes, like stations, NIMs, and HGs, would be able to be
reloaded from it. It is preferable to try to get the system HM, and other HMs
with Area Data Bases and checkpoints, up and running first and reload the
nodes from it, but a Fast Load disk is a good alternative.

The Fast Load disk needs to be updated periodically, since it contains the
current NCF, AM/CL CDS parameters that need to be loaded to stations,
checkpoints, and other critical files for the system to work correctly. The
attached procedures from the Engineering Reference Manual gives
specific instructions on how to build a Fast Load. The main steps are:

1. For a GUS or EST create a Fast Load using the EC for FAST_GUS.EC,
which you would need to create one for each Console and Area to allow
all stations to be reloaded. You can also modify a Fast Load and add
additional directories for different Areas so only 1 Fast Load would be
needed.
2. For an APP/E-APP/ACE-T/ESVT create a Fast Load using the EC for
FAST_APP.EC. It contains all AM checkpoints, so this disk can be used
on any APP/E-APP/ACE-T/ESVT.
3. For the US Operator Personality, NIM or HG personalities and including
their checkpoints from the HM, use FST_VOLZ.EC.

Note: It is recommended that once the Fast Load disk is created, you can
checkpoint all Hiway boxes for the HGs and all modules in the UCNs so
you’ll have the capability of reloading these nodes if the HMs are not
available. This also means that the Fast Load disk(s) would need to be
updated or rebuilt periodically so they would have the same file timestamps
as the ones in the HMs. Otherwise when the HMs are brought up and used
to reload nodes, you may get Warning or Severe error indications on some of
the nodes, or the database may be obsolete or missing new points due to old
checkpoints.

Identifying Need to keep track of AM/CL and HPM/CL errors from points that have
Application programs attached to them.
Failures
Frequency Daily.

Procedure Use Documentation Tool; to generate list of points with CL errors, Not
Loaded and Not Running. Compare the lists with previous lists and highlight
to operations these points.

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13. Performance Monitoring

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Performance Need to check the health of the system periodically to make sure that it’s
Monitoring running as well as expected.

Frequency Monthly (or more frequently) for displays, annually for monitoring programs.

There are three levels of Performance Monitoring which may take place:

1. Continuous Monitoring - continuous

2. Performance Baseline Monitoring -annually
3. Performance Check – monthly.

Continuous 1. Continuous Monitoring: The PERFMENU displays give instantaneous

Monitoring monitoring of important parameters. These displays, which parameters and
their value limits to look at are described in Section 25 of the CRM manual
(PD25A01A and PD25A01B). You can make an AM/CL program and
historize some of these critical parameters like PARSEC and CPUFREE.

CAUTION should be used not to historize too many node parameters to the
point of overloading the node, especially if it’s already overloaded.

Performance 2. Performance Baseline Monitoring: These are system tools installed by

Baseline Honeywell Field Service that run for a period of time, like a shift or a day, the
Monitoring data collected is sent in to Honeywell for analysis and Honeywell will issue a
report to the customer. These audit tools are called Integrated Automation
Assessments (IAA), which consist of Experion System Performance Baseline
(SPB) and TPS SPB. The TPS SPB would be run on system that don’t have
Experion nodes (just LCN/TPN nodes) or a hybrid system with LCN/TPN
(US, NIMs, HGs, AMs, etc.), TPS (GUS/APP) and Experion nodes
(EST/ESVT and ACE-T/E-APP).

The Audit Tool is used to collect hardware, software, and system-related

Audit Tool information from Experion systems. The Audit Tool uses this data to create
inventory lists that define the system in terms of its PCs and Servers (PC
Audit), its Controllers (L1 Audit), and its Switches (Switch Audit). The Audit
Tool R200.3 supports Experion releases R301.x through R431.x. It’s installed
and run by Honeywell Field Service and a report can be requested by the
customer.

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Performance 3. Performance Check: If neither of the first two procedures is in place, then
Check follow the Performance Check on system health.

Frequency Monthly.

Procedure Refer to the Engineering Reference Manual, Sections 22 and 23,

attached, for more details and information.

Print Summary Take a screen print of the following display:

Displays
1. CPUCCHKR
2. PARCHKR
3. HEAPCHKR
4. HEAPMIN
5. CLOKSTAT
6. LCNPERF (refer to the CRM PD25A01B on how to start it)

Print 10 Minute Take a 10 minute trends (code 4) for the following trend displays (for each
applicable node):
Trends
1. AMTREND
2. HGTREND
3. HMTREND
4. NIMTREND
5. NGTREND (if any NGs on the system)

Take a 10 minute QUIKTRND with each of the following values.

QUIKTRND
Call up QUIKTRND and enter $PRSTSxx.PARAMETER, where xx = node
number and PARAMETER = CPUFREE, etc.:

1. CPUFREE for all HGs and NIMs

2. CPUFREE for all AMs
3. CPUFREE for all HMs
4. GETAVGS/STRAVGS/CDSAVGS/CLAVGS for all AM
5. DHMSGSEC(1), (2), (3), (4) AND (5) for all HGs and NIMs
6. DHPARSEC(1), (2), (3), (4) AND (5) for all HGs and NIMs
7. PARSEC and REQUESTS for all HGs, NIMs and AMs.

NODEPERF Obtain a set of NODEPERF screen prints for each node on the system. Do
not leave NODEPERF on display since it can cause a node overload, print
immediately after all of the data appears and enter the next node number.

AMDETAIL Get screen prints of AMDETAIL for each AM.

Get screen prints of HMDETAIL for each HM. Set the time to 10 minutes and
HMDETAIL
allow the trend to build up.

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LCN Diagnostic Print screen for each of these displays:

Displays,
$LNMEMU Network View: Cable A Totals and Cable B Totals.
Other: Reset Times, Net Media Deads, LG Buffer Stat and SM Buffer Stat.

Using the $LNMENU display under Other, Reset the counters for all nodes.
After one day, print the above info and under Node Specific View – Nodes
That Sent Messages To Node XX, for each node.

Check under Other for Crossed Cables that the lowest node numbered
station, like US1, has a count of 1 over the rest of the nodes. Note that a
K2LCN with HW/FW revs. P/P or a K4LCN or a LCNP4 is required in the
lowest numbered station. If any of the values are not following the lowest
numbered station, you probably have a cross cable at that node (cable A
goes to B or vice versa).

SMCC From the engineering Main Menu, using SMCC/Maintenance, get screen
prints of the Module Error > Module Error Summary for each of the nodes on
the system. Review the data.

HPM Data Do screen prints of the following using PERFMENU displays for all HPMs:

1. UCNCOMM
2. UCNEVENT
3. UCNSUMM
4. NODESTA1
5. NODESTA2
6. UCNDEVUT (refer to the CRM PD25A01B)

Review Honeywell issues Priority Notifications (PNs), Be Aware (BWs), Retrofit

Announcement Letters (RALs), and Security Notifications (SNs) that should
Notifications,
be reviewed at least monthly. The HPS website would have these at:
HINTS, Other https://www.honeywellprocess.com . They are under Support under Latest
Notifications.

We also put out a System HINTS Report monthly that has good info in it,
should read it monthly. It is also in our website above under Support under
Latest Newsletters.
There are matrices, like the Experion Update Matrix, that should be reviewed
monthly. It has PNs and BWs in it, besides info on releases, patches, drivers,
hardware, etc.
Monthly
Frequency
At a station with the External Load Module (can use CBREV to check it) for
LVRLOG/AUDIT LVRLOG (or run AUDIT from the Command Processor), run and check it
against the SCNs and CRGs to make sure all nodes are running the same
release level and have good hardware and firmware in them.

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14. System Audit Checks

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Performance Need to check the general health of the system periodically to make sure that
Monitoring it’s running as well as expected.

Frequency Monthly (or more frequently) for displays, annually for monitoring programs.

See Appendix E for details and test equipment to use.

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Appendix A

Table 1 - LCN Maintenance Checklist

Date completed Activity
Make sure airflow is maintained around the LCN Node. Airflow needs to
remain unobstructed. Check and Clean Node Filters. (The frequency of
maintenance may vary depending on the environment within the control or
equipment room)
Carry out audible inspection of cabinet fans to make sure that they are
running properly
Report any excessive dust/debris noted on equipment, or on the
equipment’s air intakes or exhaust. Inspect the cards for excess dust
Check room and cabinet temperature/humidity and report any abnormal
variances to the Site Services Team Control System Administrator. Refer to
TPS System Site Planning manual SW02-550 and Local Control Network
Planning manual SW02-501
Doors on cabinets should be closed and sealed when someone is not
actively working on equipment within the cabinet. Clean cabinet air filters
Check LCN Connectors for any kind of condensation or corrosion. Verify
BNC connectors are twisted on fully
Review the System Status and System Maintenance Journals for any signs
of problems such as nodes failing, maintenance messages starting to
appear or any other abnormal indications
Review LCN communications status. In the LCN Diagnostic displays,
search for any signs of NOISE, NET MEDIA DEADS, ALONE-IN-RING etc.
Do screen prints if present. Reset all counters on completion of this review
so this gives you a starting reference point for the next period

Table 2 - LCN Maintenance Matrix

Task/Freq Weekly* Monthly* Quarterly* Annually*
Clean Nodes’ Filters X
and inspect cards
Fan Inspection X
Monitor Environment X
Review System Status X
and Maintenance
Journals
Review LCN Cable X
Communications using
LCN Diagnostic
displays and System
Error Journal

* The frequency may change based on individual node environmental conditions.

(Back to document)

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Appendix B
Table 3 - PC Maintenance Checklist
Date completed Activity
Make sure airflow is maintained around MMI Node. Airflow needs to
remain unobstructed. Check and clean Node Filters. (The frequency of
maintenance may vary depending on the environment within the control
room)
Carry out audible inspection of PC fans to make sure that they are running
properly.
Visual inspection and cleaning of PC node monitors that are accumulating
dust/debris. Clean monitors using lint-free non-abrasive cloth. Do NOT use
any cleaning agent such as Glass cleaner
Visual inspection and cleaning of MMI node keyboards and Mouse. Use a
soft cloth lightly dampened with a small amount of dishwashing soap in
water (it must not drip when squeezed). Wipe the surface of the keyboard
ensuring that no excess solution runs into the keyboard. Refer to Honeywell
Planning, Installation and Service for TPN-Connected Nodes TP38-100
Section 9.2
Report any excessive dust/debris noted on equipment, or on the
equipment’s air intakes or exhaust. Inspect the CD and zip drive for excess
dust. Vacuum out drives and use commercial off the shelf-cleaning (Non-
abrasive) product to clean the read write heads of the CD and drives.
Check room temperature and humidity and report any abnormal variances
to the Site Services Team Control System Administrator. Refer to
Honeywell Icon Series Console Planning Installation and Service Guide
HC05-200 Release 2.0 Section 2.0
Doors on cabinets should be closed and sealed when someone is not
actively working on equipment within the cabinet.
Check LCN Connectors for any kind of condensation or corrosion.
Login to GUS/EST nodes and check System Event logs for errors.

Table 4 - PC Maintenance Matrix

Task/Freq Weekly* Monthly* Quarterly* Annually*
Node Filters X
Fan Inspection X
Clean Monitors X
Clean Keyboards X
CD R/W Drive X
Floppy Drive X
Mouse X
Printers X
Lubricate latches X
Monitor X
Environment
Monitor Microsoft X
Event Logs**
* The frequency may change based on individual node environmental conditions.
** The Site Process Systems Administrator may perform this task. (Back to document)
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Appendix C

Table 5 – UCN Maintenance Checklist

Date completed Activity
Make sure airflow is maintained around the UCN Node. Airflow needs to
remain unobstructed. Check and clean Cabinet Filters. (The frequency of
maintenance may vary depending on the environment within the Equipment
room)
Check all correct LED’s are on. Verify power supply is working correctly.
Carry out audible inspection of cabinet fans to make sure that they are
running properly.
Report any excessive dust/debris noted on equipment, or on the
equipment’s air intakes or exhaust. Inspect the cards for excess dust.
Check room and cabinet temperature/humidity and report any abnormal
variances to the Site Services Team Control System Administrator. Refer to
TPS System Site Planning SW02-550, High-Performance Process Manager
Planning Guide HP02-610 and Universal Control Network Planning manual
UN02-501.
Doors on cabinets should be closed and sealed when someone is not
actively working on equipment within the cabinet. Clean cabinet air filters.
Check UCN connectors for any signs of condensation or corrosion. Check
UCN connector torque settings are correct. This needs to be done in a
controlled fashion. Lock UCN to one cable and then work on the opposite
cable to verify torque settings are correct.
Review the System Status and System Maintenance Journals for any signs
of problems such as nodes failing, maintenance messages starting to
appear or any other abnormal indications.
Review UCN communications status. Search for any signs of NOISE,
PARTIAL FRAMES, NO SUCCESSOR FOUND etc. Reset all counters on
completion of this review so this gives you a starting reference point for the
next period. Refer to Universal Control Network Guidelines UN12-510.
Perform UCN node Periodic Redundancy Tests*. Refer to High-
Performance Process Manager Service HP13-610a.
If the node contains 48 volt batteries then perform the maintenance tests
indicated in High-Performance Process Manager Service manual HP13-
610a
Check voltages across CMOS batteries. These should be 3.6-4.8volts
across all three batteries. Refer to High-Performance Process Manager
Service manual HP13-610a These batteries need to be replaced every 2
years.
If in the event you have AC only power supplies then replace the alkaline
batteries every 6 months.
* The frequency may change based on individual node environmental conditions.
(Back to document)
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PREVENTIVE MAINTENANCE PROCEDURES, Continued

Appendix D

Table 6 – Cabinet and Console Checklist

Required Checks Verifications
Cables tidy? Are cables in trays, do the trays have lids fitted, are cables
neatly tied to each other and to the cabinet structure, are extra
lengths neat?
Signal/Power Are power cables and signal cables run as separately as
separate? possible?
Cables Terminated Do cables have appropriate crimps and clean connectors? Are
Correctly? the terminators clean and reading 75 Ohms?
Cables Adequately Is it possible (with appropriate drawings if necessary) to
Identified? uniquely identify cables, and what they are connected to?
Cables Unstressed? Is there sufficient slack in the cables to ensure that there are no
excess pulling forces on I/O connections?
Cables not Check Tables in Appendix A
exceeding minimum
bends?
Power Terminals Are all cables with >50 V marked, and the terminals are
Shielded? covered to prevent accidental contact?
Grounding Correct? Check System Site Planning Manual, Section 4
Filters Clean? Are filters installed, fitted correctly and dust free?
Cabinet Sealed? Are cabinet doors closed, and cable entries gladded and/or
sealed? Are air baffles installed?
Cabinet Clean? Check for dust, and its type, i.e. sooty, metallic, etc. Examine
inside enclosures as well
Power Supplies, Clean dust, dirt, etc. off power supplies air flow intakes,
Batteries and Fans batteries and fans, especially in Series C C300 cabinets. Power
Cleaned? Supplies have failed due to dirty air flow intakes and fans in the
Power Supplies
Voltages Checked Document Voltages in Table 6, Appendix C
and OK?
Boards clean and Are boards dust and debris free? Do they have an abnormal
w/o any odors? odors as if mice nesting on them?

(Back to document)

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Appendix E

Table 7 - System Audit Checklist

Customer: Site: Date:
System Audit Checklist

Cabinet: Location:

Yes No Comments
Cables Tidy?
Signal/Power separate?
Cables Terminated Correctly?
Cables Adequately Identified?
Cables Unstressed?
Cables not exceeding min bends?
Power Terminals Shielded?
Grounding Correct?
Filters Clean?
Cabinet Sealed?
Cabinet Clean?
Voltages Checked and OK?
#1 #2
Cabinet AC Voltage Input Nominal +10%, -15%
Cabinet AC Frequency Input Nominal +3%, -6%

Yes No Comments
Peripherals OK?

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Appendix E (continued)

Table 7 - System Audit Checklist (continued)

Reading Comments
Internal Temperature 10-40 degs C, Normal = 20 degs C
External Temperature 10-40 degs C, Normal = 20 degs C
External Humidity 40-60% RH
Positive Pressure Differential >0.1” Water Gauge
Noise Level
Light Level >500 Lux
ELF Level

Yes No Comments
Good Screen Contrast?
Low Reflected Glare?

Yes No Comments
Ventilation Adequate?

Yes No Comments
Coupon Placed
Coupon Retrieved
Yes No Results
Coupon Analyzed Must be less than 300 Angstroms/Month

Summary Yes No Comments

Is this a suitable working
environment?

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Appendix E (continued)
\

Equipment Required:

 Fluke 8060A Multimeter

 Torch
 Low Frequency Electromagnetic Field Detector
 Lux Meter
 Digital Sound-level Meter
 Hand-held Humidity and Temperature Meter
 Hand-held Pressure Indicator (0-2 Bar)
 Dranetz model 626 Power Disturbance Analyzer
 Oscilloscope
 Riser Bond 1270A TDR.

Review of Test Equipment (112-001)

Honeywell ISO
Nonconforming Test Equipment – Control and Disposition
Procedures
Concerning PMs It is the responsibility of service delivery personnel to be sensitive to the need
for all equipment to be in good working order at all times. They must
therefore ensure that inspection, measuring and test equipment is controlled,
maintained, calibrated and handled in such a manner that it always conforms
to the required specifications.

Inspection, measuring and test equipment that has been identified as, or is
suspected of being; nonconforming to specification must be tagged and
segregated or disposed of immediately. If there is any question as to the
condition, accuracy or calibration status of any unit of equipment, notify your
manager and tag the equipment immediately. The tag should be clearly
visible and marked to indicate that the equipment should not be used,
because it is either defective or suspected of being defective.
Disposition may either mean that the unit is scrapped or sent to Honeywell's
subcontractor of test equipment for repair and calibration services.

When not to use Inspection, measuring and test equipment used by organizations included in
Test Equipment the Service Delivery scope shall not be used if the:

 Equipment has no repair/calibration tag or tag is illegible

 Equipment has a calibration overdue
 Measurement accuracy is unknown or questionable
 Equipment has been dropped or otherwise abused
 Seals placed over the adjustment points are broke
 Equipment has a tag indicating that it should not be used
 Accuracy data from equipment manufacturer is missing.

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Appendix E (continued)
\

Regular Equipment that typically requires regular calibration/certification by GTE:

Equipment
Calibrations and  Digital Voltmeters
Certification  Oscilloscopes
 Frequency Counters
 Pressure Calibrators
 Pressure Gauges
 Vacuum Gauges
 Dead-weight Testers
 Temperature Calibrators
 Torque Wrenches
 VOM-Digital/Analog
 Decade Boxes.

Location Equipment that could typically be set-up for location calibration or tested. The
Equipment branch should keep a log of tests and use branch calibration stickers for this
equipment:
Calibration
 Mag. Flow Calibrators
 Dial Pressure Gauges in Test Fixtures
 Power Supplies
 ESD Testers.

All equipment that requires regular calibration/certification but is not being

calibrated should when practical be segregated from other test equipment
and must be clearly marked with a label indicating so, like:

“DO NOT USE FOR CALIBRATION” or “NOT CALIBRATED.”

Honeywell Process Solutions